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European Technical ApprovalETA – 07/0168

0432

ETA-07/0168BBR VT CONA CME

External Post-tensioning System

BBR VT International LtdRingstrasse 2, 8603 Schwerzenbach (Switzerland)

www.bbrnetwork.com

0432-CPR-00299-1.308

Responsible BBR PT Specialist Company

The delivery note accompanying components of the BBR VT CONA CME Post-tensioning System will contain the CE marking.

Assembly and installation of BBR VT CONA CME tendons must only be carried out by qualified BBR PT Specialist Companies. Find the local BBR PT Specialist Company by visiting the BBR Network website www.bbrnetwork.com.

European Organisation for Technical ApprovalsEuropäische Organisation für Technische ZulassungenOrganisation Européenne pour l’Agrément technique

Guideline for European Technical Approval of Post-tensioning Kits for Prestressing of Structures

Requirements for the installation of post-tensioning kits for prestressing of structures and qualification of the specialist company and its personnel

BBR E-Trace is the trading and quality assurance platform of the BBR Network linking the Holder of Approval, BBR VT International Ltd, BBR PT Specialist Companies and the BBR Manufacturing Plant. Along with the established BBR Factory Production Control, BBR E-Trace provides effective supply chain management including installation, delivery notes and highest quality standards, as well as full traceability of components.

Year

PT Specialist Company

Company

ww

w.bbrnetwork.com

ETAG 013

CWA 14646

S P E C I ME N

Designated according to Article 29 of

Regulation (EU) No 305/2011INSTITUT FÜR BAUTECHNIK

ÖSTERREICHISCHES

www.eota.eu

Member of

Schenkenstrasse 4 1010 Vienna Ι Austria

T +43 1 533 65 50 F +43 1 533 64 23

www.oib.or.at Ι [email protected]

European Technical Assessment

ETA-07/0168 of 18.12.2017

General part

Technical Assessment Body issuing the European Technical Assessment Trade name of the construction product Product family to which the construction product belongs Manufacturer Manufacturing plant This European Technical Assessment contains This European Technical Assessment is issued in accordance with Regulation (EU) No 305/2011, on the basis of This European Technical Assessment replaces

Österreichisches Institut für Bautechnik (OIB) Austrian Institute of Construction Engineering BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands Post-tensioning kit for external prestressing of structures BBR VT International Ltd Ringstrasse 2 8603 Schwerzenbach (ZH) Switzerland BBR VT International Ltd Ringstrasse 2 8603 Schwerzenbach (ZH) Switzerland 63 pages including Annexes 1 to 33, which form an integral part of this assessment. ETAG 013, Post-Tensioning Kits for Prestressing of Structures, edition June 2002, used according to Article 66 (3) of Regulation (EU) № 305/2011 as European Assessment Document. European technical approval ETA-07/0168 with validity from 20.12.2012 to 19.12.2017.

FÜR BAUTECHNIKÖSTERREICHISCHES

Page 2 of European Technical Assessment ETA-07/0168 of 18.12.2017, replaces European technical approval ETA-07/0168 with validity from 20.12.2012 to 19.12.2017

OIB-205-058/17-021

Table of contents

EUROPEAN TECHNICAL ASSESSMENT ETA-07/0168 OF 18.12.2017 .......................................................... 1

GENERAL PART .......................................................................................................................................... 1

TABLE OF CONTENTS .................................................................................................................................. 2

REMARKS .................................................................................................................................................. 6

SPECIFIC PARTS ......................................................................................................................................... 6

1 TECHNICAL DESCRIPTION OF THE PRODUCT ........................................................................................ 6

1.1 GENERAL.......................................................................................................................................... 6

PT SYSTEM ................................................................................................................................................ 7

1.2 DESIGNATION AND RANGE OF ANCHORAGES AND COUPLERS ................................................................ 7

1.2.1 Designation ..................................................................................................................................... 7

1.2.2 Anchorage ....................................................................................................................................... 8 1.2.2.1 General ....................................................................................................................................... 8 1.2.2.2 Restressable tendon ................................................................................................................... 8 1.2.2.3 Exchangeable tendon ................................................................................................................. 8 1.2.2.4 Electrically isolated tendon ......................................................................................................... 9 1.2.2.5 Exchangeable and electrically isolated tendon ............................................................................ 9

1.2.3 Fixed and stressing coupler ............................................................................................................. 9 1.2.3.1 Single plane coupler, FK, SK ...................................................................................................... 9 1.2.3.2 Sleeve coupler, FH, SH ............................................................................................................ 10 1.2.3.3 Electrically isolated fixed and stressing coupler ........................................................................ 10

1.3 TENDON WITH MONOSTRANDS ......................................................................................................... 10

1.4 LAYOUT OF THE ANCHORAGE RECESSES ........................................................................................... 10

1.5 DESIGNATION AND RANGE OF THE TENDONS ..................................................................................... 11

1.5.1 Designation ................................................................................................................................... 11

1.5.2 Range ........................................................................................................................................... 11 1.5.2.1 General ..................................................................................................................................... 11 1.5.2.2 CONA CMI n06-140 .................................................................................................................. 11 1.5.2.3 CONA CMI n06-150 .................................................................................................................. 12

1.6 DUCT ............................................................................................................................................. 12

1.7 FRICTION LOSSES ........................................................................................................................... 12

1.8 SLIP AT ANCHORAGES AND COUPLERS .............................................................................................. 13

1.9 CENTRE SPACING AND EDGE DISTANCE FOR ANCHORAGES ................................................................ 14

1.10 MINIMUM RADII OF CURVATURE ........................................................................................................ 14

1.11 CONCRETE STRENGTH AT TIME OF STRESSING .................................................................................. 14

1.12 DEVIATOR ....................................................................................................................................... 15

1.12.1 General ..................................................................................................................................... 15

1.12.2 Pre-installed single tube deviator .............................................................................................. 15

1.12.3 Double tube deviator ................................................................................................................. 15

COMPONENTS .......................................................................................................................................... 15

1.13 PRESTRESSING STEEL STRAND ........................................................................................................ 15



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1.14 ANCHORAGE AND COUPLER ............................................................................................................. 16

1.14.1 General ..................................................................................................................................... 16

1.14.2 Anchor head ............................................................................................................................. 16

1.14.3 Bearing trumplate ..................................................................................................................... 16

1.14.4 Trumpet .................................................................................................................................... 16

1.14.5 Coupler anchor head K and H ................................................................................................... 16

1.14.6 Components for electrically isolated anchorage and coupler..................................................... 17

1.14.7 Ring wedges ............................................................................................................................. 17

1.14.8 Helix and additional reinforcement ............................................................................................ 17

1.14.9 Protection caps ......................................................................................................................... 17 1.14.9.1 General ..................................................................................................................................... 17 1.14.9.2 Protection caps, long protection cap ......................................................................................... 18

1.15 DUCTS ........................................................................................................................................... 18

1.15.1 Plastic duct ............................................................................................................................... 18

1.15.2 Steel duct.................................................................................................................................. 18

1.16 MATERIAL SPECIFICATIONS .............................................................................................................. 18

1.17 PERMANENT CORROSION PROTECTION ............................................................................................. 18

1.18 MONOSTRAND ................................................................................................................................ 19

2 SPECIFICATION OF THE INTENDED USES IN ACCORDANCE WITH THE APPLICABLE EUROPEAN

ASSESSMENT DOCUMENT (HEREINAFTER EAD) ................................................................................ 19

2.1 INTENDED USES .............................................................................................................................. 19

2.2 ASSUMPTIONS ................................................................................................................................ 19

2.2.1 General ......................................................................................................................................... 19

2.2.2 Packaging, transport, and storage ................................................................................................. 20

2.2.3 Design ........................................................................................................................................... 20 2.2.3.1 General ..................................................................................................................................... 20 2.2.3.2 Anchorage Recess ................................................................................................................... 20 2.2.3.3 Maximum prestressing force ..................................................................................................... 20 2.2.3.4 Centre spacing, edge distance, and reinforcement in the anchorage zone ............................... 20 2.2.3.5 Fixed coupler ............................................................................................................................ 21 2.2.3.6 Tendons in masonry structures – Load transfer to the structure ................................................ 21

2.2.4 Installation ..................................................................................................................................... 21 2.2.4.1 General ..................................................................................................................................... 21 2.2.4.2 Monostrand tendons ................................................................................................................. 21 2.2.4.3 Electrically isolated tendon ....................................................................................................... 22 2.2.4.4 Stressing operation ................................................................................................................... 22 2.2.4.5 Restressing ............................................................................................................................... 22 2.2.4.6 Filling operations ....................................................................................................................... 23 2.2.4.6.1 Grouting ................................................................................................................................. 23 2.2.4.6.2 Filling with corrosion protection filling material ........................................................................ 23 2.2.4.7 Exchange of tendons ................................................................................................................ 23 2.2.4.8 Welding .................................................................................................................................... 23

2.3 ASSUMED WORKING LIFE ................................................................................................................. 24

3 PERFORMANCE OF THE PRODUCT AND REFERENCES TO THE METHODS USED FOR ITS ASSESSMENT ..... 24



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3.1 ESSENTIAL CHARACTERISTICS ......................................................................................................... 24

3.2 PRODUCT PERFORMANCE ................................................................................................................ 26

3.2.1 Mechanical resistance and stability ............................................................................................... 26 3.2.1.1 Resistance to static load ........................................................................................................... 26 3.2.1.2 Resistance to fatigue ................................................................................................................ 26 3.2.1.3 Load transfer to the structure .................................................................................................... 26 3.2.1.4 Friction coefficient ..................................................................................................................... 27 3.2.1.5 Deviation, deflection (limits) ...................................................................................................... 27 3.2.1.6 Practicability, reliability of installation ........................................................................................ 27

3.2.2 Hygiene, health, and the environment ........................................................................................... 27

3.2.3 Related aspects of serviceability ................................................................................................... 27

3.2.4 Mechanical resistance and stability ............................................................................................... 27 3.2.4.1 Restressable external tendon – Practicability, reliability of installation ...................................... 27 3.2.4.2 Exchangeable external tendon – Practicability, reliability of installation ..................................... 27 3.2.4.3 Electrically isolated tendon – Practicability, reliability of installation........................................... 27 3.2.4.4 Tendons in masonry structures – Load transfer to the structure ................................................ 27

3.3 ASSESSMENT METHODS .................................................................................................................. 27

3.4 IDENTIFICATION ............................................................................................................................... 28

4 ASSESSMENT AND VERIFICATION OF CONSTANCY OF PERFORMANCE (HEREINAFTER AVCP) SYSTEM APPLIED, WITH REFERENCE TO ITS LEGAL BASE..................................................................... 28

4.1 SYSTEM OF ASSESSMENT AND VERIFICATION OF CONSTANCY OF PERFORMANCE................................. 28

4.2 AVCP FOR CONSTRUCTION PRODUCTS FOR WHICH A EUROPEAN TECHNICAL ASSESSMENT HAS

BEEN ISSUED .................................................................................................................................. 28

5 TECHNICAL DETAILS NECESSARY FOR THE IMPLEMENTATION OF THE AVCP SYSTEM, AS PROVIDED

FOR IN THE APPLICABLE EAD ........................................................................................................... 29

5.1 TASKS FOR THE MANUFACTURER ..................................................................................................... 29

5.1.1 Factory production control ............................................................................................................. 29

5.1.2 Declaration of performance ........................................................................................................... 29

5.2 TASKS FOR THE NOTIFIED PRODUCT CERTIFICATION BODY ................................................................. 29

5.2.1 Initial inspection of the manufacturing plant and of factory production control ................................ 29

5.2.2 Continuing surveillance, assessment, and evaluation of factory production control ....................... 30

5.2.3 Audit-testing of samples taken by the notified product certification body at the manufacturing plant or at the manufacturer's storage facilities .............................................................................. 30

ANNEXES ................................................................................................................................................. 31

ANNEX 1 OVERVIEW ON ANCHORAGES AND COUPLERS ........................................................................... 31

ANNEX 2 OVERVIEW ON ANCHORAGES AND COUPLERS ........................................................................... 32

ANNEX 3 COMPONENTS – ANCHORAGE AND COUPLER ........................................................................... 33

ANNEX 4 COMPONENTS – ANCHORAGE AND COUPLER ........................................................................... 34

ANNEX 5 COMPONENTS – ACCESSORY ................................................................................................. 35


ANNEX 7 ELECTRICALLY ISOLATED TENDON – COMPONENTS – ANCHORAGE AND ACCESSORY .................. 37


ANNEX 9 DEVIATOR AND STRAIGHT LENGTH ........................................................................................... 39



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ANNEX 10 DUCT .................................................................................................................................... 40

ANNEX 11 MATERIAL SPECIFICATIONS ..................................................................................................... 41

ANNEX 12 STRAND SPECIFICATIONS ........................................................................................................ 42

ANNEX 13 TENDON RANGES ................................................................................................................... 43

ANNEX 14 TENDON RANGES ................................................................................................................... 44

ANNEX 15 MAXIMUM PRESTRESSING AND OVERSTRESSING FORCES ......................................................... 45

ANNEX 16 MINIMUM CENTRE SPACING ..................................................................................................... 46

ANNEX 17 MINIMUM EDGE DISTANCE ....................................................................................................... 47

ANNEX 18 ANCHORAGE ZONE – DIMENSIONS – HELIX AND ADDITIONAL REINFORCEMENT AND SPACING ....... 48






ANNEX 24 ANCHORAGE ZONE – DIMENSIONS – MODIFICATION OF CENTRE SPACING AND EDGE

DISTANCE .............................................................................................................................. 54

ANNEX 25 CONSTRUCTION STAGES......................................................................................................... 55

ANNEX 26 CONSTRUCTION STAGES......................................................................................................... 56

ANNEX 27 DESCRIPTION OF INSTALLATION .............................................................................................. 57

ANNEX 28 DESCRIPTION OF INSTALLATION .............................................................................................. 58

ANNEX 29 CONTENTS OF THE PRESCRIBED TEST PLAN ............................................................................. 59

ANNEX 30 AUDIT TESTING ...................................................................................................................... 60

ANNEX 31 ESSENTIAL CHARACTERISTICS FOR THE INTENDED USES ........................................................... 61

ANNEX 32 REFERENCE DOCUMENTS ....................................................................................................... 62

ANNEX 33 REFERENCE DOCUMENTS ....................................................................................................... 63



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Remarks

Translations of the European Technical Assessment in other languages shall fully correspond to the original issued document and should be identified as such.

Communication of the European Technical Assessment, including transmission by electronic means, shall be in full. However, partial reproduction may be made with the written consent of Österreichisches Institut für Bautechnik. Any partial reproduction has to be identified as such.

Specific parts

1 Technical description of the product

1.1 General

The European Technical Assessment1 – ETA – applies to a kit, the PT system

BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands,

comprising the following components, see Annex 1 and Annex 2.

Tendon

External tendon with 04 to 61 tensile elements

Tensile element

7-wire prestressing steel strand with nominal diameters and maximum characteristic tensile strength as given in Table 1.

7-wire prestressing steel strands with nominal diameters and maximum characteristic tensile strength as given in Table 1, factory-provided with a corrosion protection system, comprising corrosion protection filling material and HDPE-sheathing – Monostrand.

Tendon with monostrands is installed in one common duct and grouted prior to stressing.

Table 1 Tensile elements

Nominal diameter Nominal cross-sectional

area Maximum characteristic

tensile strength

mm mm2 MPa

15.3 140 1 860

15.7 150

NOTE 1 MPa = 1 N/mm2

Anchorage of the prestressing steel strands with ring wedges

1 ETA-07/0168 was firstly issued in 2006 as European technical approval with validity from 25.08.2006, extended

in 2011 with validity from 05.07.2011, amended in 2013 with validity from 04.03.2013, converted in 2016 to European Technical Assessment ETA-07/0168 of 20.12.2012 to 19.12.2017, and amended in 2017 to European Technical Assessment ETA-07/0168 of 18.12.2017



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End anchorage

Fixed (passive) anchor or stressing (active) anchor as end anchorage (SA, FA) for tendons with 04, 07, 09, 12, 15, 19, 22, 24, 27, 31, 37, 42, 43, 48, 55, and 61 prestressing steel strands

Fixed (passive) anchor or stressing (active) anchor as end anchorage for replaceable tendons (SAR, FAR) with 04, 07, 09, 12, 15, 19, 22, 24, 27, 31, 37, 42, 43, 48, 55, and 61 prestressing steel strands

Fixed (passive) anchor or stressing (active) anchor for electrically isolated tendons (SAE, FAE) with 04, 07, 09, 12, 15, 19, 22, 24, 27, and 31 prestressing steel strands

Fixed (passive) anchor or stressing (active) anchor for replaceable and electrically isolated tendons (SAER, FAER) with 04, 07, 09, 12, 15, 19, 22, 24, 27, and 31 prestressing steel strands

Fixed or stressing coupler

Single plane coupler (FK, SK) for tendons with 04, 07, 09, 12, 15, 19, 22, 24, 27, and 31 prestressing steel strands

Sleeve coupler (FH, SH) for tendons with 04, 07, 09, 12, 15, 19, 22, 24, 27, 31, 37, 42, 43, 48, 55, and 61 prestressing steel strands

Sleeve coupler (FHE, SHE) for electrically isolated tendons with 04, 07, 09, 12, 15, 19, 22, 24, 27, and 31 prestressing steel strands

Bearing trumplate for tendons with 04, 07, 09, 12, 15, 19, 22, 24, 27, 31, 37, 42, 43, 48, 55, and 61 prestressing steel strands

Helix and additional reinforcement in the region of the anchorage

Ducts in steel or plastic

Corrosion protection for tensile elements, couplers, and anchorages

PT system

1.2 Designation and range of anchorages and couplers

1.2.1 Designation

End anchorage, e.g. S A (E) CONA CME 1906-150 1860

Stressing (S) or fixed (F)

Anchor head (A)

Optional tendon use None ( ), Electrically isolated (E), Replaceable (R), Electrically isolated and replaceable (ER)

Designation of the tendon with information on number, cross-sectional area, and characteristic tensile strength of the prestressing steel strands



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Coupler, e.g. F K (E) CONA CME 1906-150 1860

Fixed (F) or stressing (S)

Coupler anchor head (K or H)

Optional tendon use None ( ), Electrically isolated (E)

Designation of the tendon with information on number, cross-sectional area, and characteristic tensile strength of the prestressing steel strands

Anchor head A is supported on bearing trumplate A that transmits the force to the structural concrete. In the region of the anchorage, the structural concrete is confined with helix and additional reinforcement.

1.2.2 Anchorage

1.2.2.1 General

Anchorage of prestressing steel strands is achieved by wedges and anchor heads A, see Annex 1, Annex 2, and Annex 3. The anchor heads A of stressing and fixed anchorages are identical. A differentiation is needed for the construction works.

The wedges of inaccessible fixed anchors are secured with either a wedge retaining plate or springs and a wedge retaining plate. An alternative is pre-locking each individual prestressing steel strand with ~ 0.5 · Fpk and applying a wedge retaining plate.

Where

Fpk ......... N.............. Characteristic value of maximum force of one single prestressing steel strand

1.2.2.2 Restressable tendon

For tendons remaining restressable throughout the working life of the structure, grease, wax, or an equivalent soft material is used. This is applicable to

Bare strands in a common duct and

Monostrands, grouted in a common duct.

Bare strands, grouted in a common duct are not restressable.

Significant to a restressable tendon is the excess length of the prestressing steel strands, see Annex 1. The extent of the excess length depends on the jack used for restressing and where applicable, the elongation for a full release of the prestressing force of the tendon. The protrusions of the prestressing steel strands require a permanent corrosive protection and an adapted protection cap.

1.2.2.3 Exchangeable tendon

Exchanging tendons in general is available for

Bare strands with grease, wax, or an equivalent soft material in a common duct

Monostrands, grouted in a common duct, see Clause 1.3

Bare strands, grouted in a common duct, can only be completely removed and subsequently replaced by a new tendon, see Annex 2, anchorages FAR and SAR for replaceable tendons. Inner trumpet A is placed in bearing trumplate A and trumpet A, extends up to anchor head A and provides a separating layer between structure and tendon. After full release of the



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prestressing force, the complete tendon with inner trumpet A can be pulled out from the structure and replaced by a new tendon.

1.2.2.4 Electrically isolated tendon

The anchorage of an electrically isolated tendon, see Annex 2, comprises the following components.

Fixed and stressing anchorage according to Clause 1.2.2.1.

Steel ring E, see Annex 7

Isolation ring E, see Annex 7

Bearing trumplate E, see Annex 7

Trumpet E, see Annex 7

Plastic duct, see Annex 10

Protection cap E, see Annex 7

Trumpet E continues through bearing trumplate E up to steel ring E. For electrically isolated tendon isolation ring E is placed between bearing trumplate E and steel ring E. Steel ring E supports the anchor head A. Protection cap E encases the anchorage and provides a port as inlet or vent that is sealed with a plug.

With electrically isolated tendon, the complete tendon, i.e. including prestressing steel strands, anchorages, and couplers, is fully encased with isolation material. The integrity of the electrical isolation can be verified and monitored via electrical resistance measurements between tendon and reinforcement of the structure.

1.2.2.5 Exchangeable and electrically isolated tendon

Exchanging electrically isolated tendons in general is available for

Bare strands with grease, wax, or an equivalent soft material in a common duct

Monostrands, grouted in a common duct, see Clause 1.3

Bare strands, grouted in a common duct, can only be completely removed and replaced with a new tendon, see Annex 2, anchorages FAER and SAER for replaceable and electrically isolated tendons. Inner trumpet E, see Annex 8, is placed in bearing trumplate E and trumpet A, extends up to steel ring E and provides a separating layer between structure and tendon. Anchorage and tendon comprises the following components.

Steel ring E, see Annex 7

Isolation ring E, see Annex 7

Bearing trumplate E, see Annex 7

Trumpet A, see Annex 5, together with inner trumpet E, see Annex 8

Plastic duct, see Annex 10

Protection cap E, see Annex 7

After full release of the prestressing force, the complete tendon with inner trumpet E can be pulled out from the structure and replaced by a new tendon.

1.2.3 Fixed and stressing coupler

1.2.3.1 Single plane coupler, FK, SK

The coupling is achieved by means of a coupler anchor head K, see Annex 1 and Annex 3. The prestressing steel strands of the first construction stage are anchored by means of wedges in



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machined cones, drilled in parallel. The arrangement of the cones of the first construction stage is identical to that of anchor head A of the stressing anchorage. The prestressing steel strands of the second construction stage are anchored in a circle around the cones of the first construction stage by means of wedges in machined cones, drilled at an inclination of 7 °. The wedges for the second construction stage are secured by springs and a cover plate.

The transition trumpet to duct in steel is provided with a 100 mm long and at least 3.5 mm thick PE-HD insert at the deviating point at the end of the trumpet. The insert is not required for plastic trumpets, where the ducts are slipped over the plastic trumpets.

1.2.3.2 Sleeve coupler, FH, SH

The coupler anchor head H, see Annex 1, Annex 2, and Annex 4, is of the same basic geometry as anchor head A of the fixed and stressing anchor. Compared to anchor head A of the fixed and stressing anchor, the coupler anchor head H is deeper and provide an external thread for the coupler sleeve H.

The connection between the coupler anchor heads H of first and second construction stage is achieved by means of a coupler sleeve H.

The transition trumpet to duct in steel is provided with a 100 mm long and at least 3.5 mm thick PE-HD insert at the deviating point at the end of the trumpet. The insert is not required for plastic trumpets, where the ducts are slipped over the plastic trumpets.

1.2.3.3 Electrically isolated fixed and stressing coupler

The electrically isolated fixed and stressing coupler, see Annex 2, is a sleeve coupler and comprises the following components.

Electrically isolated stressing anchorage according to Clause 1.2.2.4 at the first construction stage with coupler anchor head H.

Second construction stage and connection of first and second construction stage with a sleeve coupler according to Clause 1.2.3.2.

Plastic housing to fully encase the fixed or stressing coupler with isolation material.

1.3 Tendon with monostrands

The tendon comprises monostrands in one common duct that is grouted prior to stressing. During grouting a sealing plate together with an activation plate is installed at the anchorage to arrange the monostrands and resist the grouting pressure. After grouting the monostrand ends are de-sheathed. For stressing, the anchor head A is placed on the grouted tendon.

Stressing can be commenced, once compressive strength of the grout is sufficiently developed.

This is in general not before a compressive strength of 10 MPa is attained by the grout.

Tendon with monostrands allows for the smallest deflection radius of the tendon.

Exchange of tendons with monostrands is in general performed according to the Clauses 1.2.2.3 and 2.2.4.7. Tendons with straight tendon paths – or tendon paths that exhibit slight deviations only – can be exchanged in a strand-by-strand procedure, individually for each monostrand. However, after exchanging the prestressing steel strands, the monostrands are sufficiently completed with corrosion protection filling material.

1.4 Layout of the anchorage recesses

All bearing trumplates, anchor heads, and coupler heads are placed perpendicular to the axis of the tendon, see Annex 25.

The dimensions of the anchorage recesses are adapted to the prestressing jacks used. The ETA holder saves for reference information on the minimum dimensions of the anchorage recesses.



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The formwork for the anchorage recess should be slightly conical for ease of removal. In case of anchorage fully embedded in concrete, the recess is designed so as to permit a reinforced concrete cover with the required dimensions and in any case with a thickness of at least 20 mm. In case of exposed anchorage, concrete cover of anchorage and bearing trumplate is not required. However, the exposed surfaces of bearing trumplate and steel cap are provided with corrosion protection.

1.5 Designation and range of the tendons

1.5.1 Designation

Tendon, e.g. CONA CME 19 06-150 1860

External PT

Number of strands, 04 to 61

Prestressing steel strand

Cross-sectional area of strand, 140 or 150 mm2

Characteristic tensile strength of strand

The tendons comprise 04 to 61 tensile elements, 7-wire prestressing steel strands according to Annex 12.

1.5.2 Range

1.5.2.1 General

Characteristic maximum force of tendon with 04 to 61 prestressing steel strands are listed in Annex 13 and Annex 14.

Prestressing and overstressing forces are applied according to the corresponding standards and regulations in force at the place of use. The maximum prestressing and overstressing forces according to Eurocode 2 are listed in Annex 15.

The tendons consist of 04, 07, 09, 12, 15, 19, 22, 24, 27, 31, 37, 42, 43, 48, 55, or 61 prestressing steel strands. By omitting prestressing steel strands in the anchorages and couplers in a radially symmetrical way, also tendons with numbers of strands lying between the numbers given above can be installed. Any unnecessary hole either remains undrilled or is provided with a short piece of prestressing steel strand and a wedge is inserted. For coupler anchor head K the cones of the outer pitch circle, second construction stage, may be equally redistributed if prestressing steel strands are omitted. However, the overall dimensions of the coupler anchor head K remain unchanged.

With regard to dimensions and reinforcement, anchorages and couplers with omitted prestressing steel strands remains unchanged compared to anchorages and couplers with a full number of prestressing steel strands.

1.5.2.2 CONA CMI n06-140

7-wire prestressing steel strand

Nominal diameter ................................................... 15.3 mm

Nominal cross-sectional area .................................. 140 mm2

Maximum characteristic tensile strength ............... 1 860 MPa

Annex 13 lists the available tendon range for CONA CMI n06-140.



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1.5.2.3 CONA CMI n06-150

7-wire prestressing steel strand

Nominal diameter ................................................... 15.7 mm

Nominal cross-sectional area .................................. 150 mm2

Maximum characteristic tensile strength ............... 1 860 MPa

Annex 14 lists the available tendon range for CONA CMI n06-150.

1.6 Duct

Ducts are either in plastic or in steel. The inner diameter of the duct meets the requirements of Table 2.

f = cross-sectional area of prestressing steel

cross-sectional area of inner diameter of duct

kD = Inner diameter of the duct

cross-sectional area of prestressing steel

Where

f ............ ― .............. degree of filling

kD .......... ― .............. duct coefficient

Table 2 Degree of filling and duct coefficient

Duct f kD 1)

Minimum 2) 0.45 1.68

Standard 0.40 1.79

Long tendons 0.30–0.35 2.05–1.90

1) Minimum value according to ENV 1992-1-5 2, clause 1.6

2) Not for wax injection of PE-duct

Exemplary values of duct sizes are shown in Annex 10.

Jointing and sealing of the ducts can be performed by welding or by non welding jointing techniques, e.g. sleeves and collars. If the joints are resistant to the injection pressure according to ENV 1992-1-5, an internal pressure of at least 1 N/mm2 is observed.

1.7 Friction losses

For calculation of loss of prestressing force due to friction, Coulomb's law applies. Calculation of friction loss is by the equation

Fx = F0 · e ·

Where

2 Standards and Guidelines and other documents referred to in the European Technical Assessment are listed in

Annex 32 and Annex 33.



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Fx .......... kN ............. Prestressing force at a distance x along the tendon

F0 .......... kN ............. Prestressing force at x = 0 m

......... rad-1 ............ Friction coefficient, see Table 3

.......... rad ............. Sum of the angular displacements over the distance x, irrespective of direction or sign

x ........... m .............. Distance along the tendon from the point where the prestressing force is equal to F0

NOTE 1 1 rad = 1 m/m = 1

NOTE 2 Wobble effects may be neglected for external tendons.

Table 3 Friction coefficient

Duct

Recommended values Range of values

µ µ

rad-1 rad-1

Bare strands in smooth steel duct 0.18 0.16–0.24

Bare strands in smooth plastic duct 0.12 0.10–0.14

Monostrands in duct and grouted 0.05

Table 4 Friction losses in anchorages

Tendon Fs

%

CONA CME 0406 1.2

CONA CME 0706 1.1

CONA CME 0906 1.0

CONA CME 1206 to 3106 0.9

CONA CME 3706 to 6106 0.8

Where

Fs ........ % .............. Friction loss in anchorages and first construction stage of fixed couplers. This is taken into account for determination of elongation and prestressing force along the tendon.

1.8 Slip at anchorages and couplers

Slip at stressing anchorages, at fixed anchorages, and at fixed couplers, first and second construction stages, is 6 mm. At stressing anchorage and at first construction stage of fixed couplers the slip is 4 mm, provided a prestressing jack with a wedge system and a wedging force of around 25 kN per prestressing steel strand is used.



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1.9 Centre spacing and edge distance for anchorages

In general, spacing and distances are not less than given in Annex 16, Annex 17, Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23. However, centre spacing of tendon anchorages may be reduced in one direction by up to 15 %, but not smaller than the outside diameter of the helix and placing of additional reinforcement is still possible. In this case centre spacing in the perpendicular direction is increased by the same percentage, see also Annex 24. The corresponding edge distances are calculated by

ae = ac

2 10 mm c

be = bc

2 10 mm c

Where

ac ......... mm ............ Centre spacing

bc ......... mm ............ Centre spacing in the direction perpendicular to ac

ae ......... mm ............ Edge distance

be ......... mm ............ Edge distance in the direction perpendicular to ae

c .......... mm ............ Concrete cover

The minimum values for ac, bc, ae, and be are given in Annex 16, Annex 17, Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23.

Standards and regulations on concrete cover in force at the place of use are observed.

1.10 Minimum radii of curvature

In Annex 10 the minimum radii of curvature of the tendon, Rmin, are given versus the number of prestressing steel strands in the tendon.

The tendon with monostrands, grouted prior to stressing, provides the smallest radius of curvature.

For smaller radii, stresses in tensile elements and wear of the duct need to be verified.

1.11 Concrete strength at time of stressing

Concrete in conformity with EN 206 is used.

At the time of stressing, the mean concrete compressive strength, fcm, 0, is at least according to Table 5. The concrete test specimens are subjected to the same hardening conditions as the structure.

For partial stressing with 30 % of the full prestressing force, the actual mean value of concrete compressive strength is at least 0.5 · fcm, 0, cube or 0.5 · fcm, 0, cylinder. Intermediate values may be interpolated linearly according to Eurocode 2.

Table 5 Compressive strength of concrete

Mean concrete strength, fcm, 0

Cube strength 150 mm cube fcm, 0, cube MPa 23 28 34 38 43

Cylinder strength, 150 mm cylinder diameter fcm, 0, cylinder

MPa 19 23 28 31 35



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Helix, additional reinforcement, centre spacing, and edge distance corresponding to the concrete compressive strengths are taken from Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23, see also the Clauses 1.14.8 and 2.2.3.4.

1.12 Deviator

1.12.1 General

The deviator transfers the forces generated by the tendon, transversal (radial to the deviator) and longitudinal (tangential to the deviator), to the structure. Moreover, the deviator provides a smooth surface for the tendon. The deviator can be made of concrete, steel, or of other material, equivalent in terms of structural and surface requirements. Permanent inserts for deviators of concrete can be made of PE-HD, steel, or of equivalent material to meet the surface requirements.

To avoid any kinking of the tendon, it is recommended to provide an additional deviation, , of

e.g. 3 °, see Annex 9.

For grouting or for filling the ducts with corrosion protection filling material, vents are provided or vacuum grouting is applied.

1.12.2 Pre-installed single tube deviator

The deviator is a pre-bent tube that is part of the tendon conduit, see Annex 9. The duct of the tendon is jointed to both ends of the tube.

Jointing between duct and deviator can be by sleeves, collars, or by welding

1.12.3 Double tube deviator

The deviator is a pre-formed recess unit of the structure that is not part of the tendon conduit. The duct of the tendon is passed through the recess unit, see Annex 9.

Components

1.13 Prestressing steel strand

Only 7-wire prestressing steel strands with characteristics according to Table 6 are used, see also Annex 12. The corrosion protection system of the monostrands, comprising corrosion protection filling material and HDPE-sheathing, is as specified in Clause 1.18.

Table 6 Prestressing steel strands and monostrands

Maximum characteristic tensile strength 1) fpk MPa 1 860

Nominal diameter d mm 15.3 15.7

Nominal cross-sectional area Ap mm2 140 150

Mass of prestressing steel M kg/m 1.093 1.172

Monostrands

Mass of monostrand kg/m 1.23 1.31

External diameter of HDPE-sheathing mm 19.5 20

1) Prestressing steel strands with a characteristic tensile strength below 1 860 MPa may also be used.

In a single tendon, only prestressing steel strands spun in the same direction are used.



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In the course of preparing the European Technical Assessment, no characteristic has been assessed for the prestressing steel strands. In execution, a suitable prestressing steel strand that conforms to Annex 12 and is according to the standards and regulations in force at the place of use is taken.

1.14 Anchorage and coupler

1.14.1 General

The components of anchorages and couplers are in conformity with the specifications given in Annex 3, Annex 4, Annex 5, Annex 6, Annex 7, and Annex 8 and the technical file3. Therein the component dimensions, materials, and material identification data with tolerances are given.

1.14.2 Anchor head

The anchor head A is made of steel and provides regularly arranged conical holes, drilled in parallel to accommodate prestressing steel strands and wedges, see Annex 3. In addition, threaded bores may be provided to attach protection caps and wedge retaining plates. At the back of the anchor head A there may be a step for ease of centring the anchor head A on bearing trumplate A or E, or on steel ring E.

1.14.3 Bearing trumplate

The bearing trumplate, made of cast iron, transmits the force via 3 anchorage planes to the concrete. Air-vents are situated at the top and at the interface plane to the anchor head. A ventilation tube can be fitted to these air-vents. On the tendon sided end, there is an inner thread to take the trumpet.

There are two bearing trumplates. Firstly, bearing trumplate A with trumpet A, see Annex 4, and secondly, bearing trumplate E, see Annex 7, for electrically isolated tendons with trumpet E.

1.14.4 Trumpet

The conical trumpets A, K, and H, see Annex 5, are made either of steel, PE, or PP, and the conical trumpet E, inner trumpet A, and inner trumpet E, see Annex 8, are made of PE or PP. Inner trumpet A and inner trumpet E are used together with trumpet A in PE or PP.

The trumpets manufactured in steel have a corrugated or plain surface. In case the transition from trumpet to duct is made in steel, a 100 mm long and at least 3.5 mm thick PE-HD insert is installed at the deviating point of the prestressing steel strands.

The conical trumpets made of PE may have either a corrugated or a plain surface. At the duct-side end, there is a radius for the deviation of the prestressing steel strands and a smooth surface, to ensure a good transition to the duct. The opposite end is connected to the bearing trumplate.

1.14.5 Coupler anchor head K and H

Coupler anchor head K, see Annex 3, for the single plane coupler is made of steel and provide in the inner part for anchorage the prestressing steel strands of the first construction stage the same arrangement of holes as the anchor head A for the stressing or fixed anchorages. In the outer pitch circle, there is an arrangement of holes with an inclination of 7 ° to accommodate the prestressing steel strands of the second construction stage. A cover plate is fastened by means of additional threaded bores.

Coupler anchor head H, see Annex 4, for the sleeve coupler H is made of steel and has the same basic geometry as the anchor head A of the stressing or fixed anchorages. Compared to the anchor head A of the fixed and stressing anchor, coupler anchor head H is deeper and provides

3 PL2 and PL3 are protection levels according to fib bulletin 33.



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an external thread for coupler sleeve H. Wedge retaining plate H is fastened by means of additional threaded bores.

The coupler sleeve H is a steel tube with an inner thread and provided with ventilation holes.

At the back of the coupler anchor heads K and H there is a step for ease of centring the coupler anchor head on bearing trumplates A or E, or on steel ring E.

1.14.6 Components for electrically isolated anchorage and coupler

Electrically isolation is achieved by an isolation ring E placed between bearing trumplate E and steel ring E, see Annex 2 and Annex 7. Steel ring E serves for load distribution of the prestressing force from anchor head A via isolation ring E to bearing trumplate E.

For full encapsulation of the tendon with isolation material, trumpet E or inner trumpet E, see Clause 1.2.2.4 and Clause 1.2.2.5, extend up to steel ring E.

1.14.7 Ring wedges

The ring wedges, see Annex 3, are in either two pieces or three pieces. Four different ring wedges are used.

Ring wedge H in three pieces, fitted with spring ring, is available in two different materials

Ring wedge F in three pieces, without spring ring or fitted with spring ring, is made of one material.

Ring wedge Z in two pieces, without spring ring or fitted with spring ring, is made of one material.

Within one anchorage or coupler, only one of these ring wedges is used.

In the case of fixed anchors and couplers, the wedges are held in place by a wedge retaining plate, by springs with a wedge retaining plate, or by springs with a cover plate. An alternative is pre-locking each individual prestressing steel strand with ~ 0.5 · Fpk and applying a wedge retaining plate as per Clause 1.2.2.1.

Where

Fpk ......... N .............. Characteristic value of maximum force of one single prestressing steel strand

1.14.8 Helix and additional reinforcement

Helix and additional reinforcement are made of ribbed reinforcing steel. The end of the helix on the anchorage side is welded to the next turn. The helix is placed exactly in the tendon axis. The helix dimensions conform to the values specified in Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23.

If required for a specific project design, the reinforcement given in Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23 may be modified in accordance with the respective regulations in force at the place of use as well as with the relevant approval of the local authority and of the ETA holder to provide equivalent performance.

1.14.9 Protection caps

1.14.9.1 General

Recessed and exposed anchorages without permanent protection caps with vents are not executed. All inaccessible or accessible fixed anchorages FA are equipped with protection caps to ensure a fully continuous corrosion protection of the tendon, from all wedges of the one end to all wedges of the other end.



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1.14.9.2 Protection caps, long protection cap

The protection caps A and E, and the long protection cap, see Annex 1, Annex 2, Annex 6, and Annex 7, are provided with an air-vent and attached to the anchorage with screws or threaded rods. The protection caps are permanent. Protection cap A is made of steel or plastic, protection cap E is made of plastic, and the long protection cap is made of steel or plastic.

Protection cap A in steel fully encases anchor head A with ring wedges and is left in place after filling. The permanent steel cap is used for inaccessible and accessible fixed anchorages FA, and for stressing anchorages SA and SAR.

Protection cap A in plastic, see Annex 6, is a UV-protected plastic cap that fully encases anchor head A and ring wedges. The protection cap is permanent and for one-time use only. The protection cap is used for inaccessible and accessible fixed anchorages FA, and for stressing anchorages SA and SAR.

Protection cap E in plastic, see Annex 7, is a permanent UV-protected plastic cap that fully encases anchor head A and ring wedges. The protection cap is permanent and for one-time use only. Protection cap E is used for electrically isolated tendons. In particular it is attached to electrically isolated inaccessible and accessible fixed anchorages FAE and stressing anchorages SAE and SAER. After filling, all inlet and outlet ports of the electrically isolated tendon are sealed with suitable plugs to provide fully electrically isolation.

The long protection cap in steel, see Annex 6, fully encases anchor head A with ring wedges and is left in place after filling. The permanent steel cap is used for restressable and exchangeable tendons at the stressing anchorages SA and SAR to protect the strand protrusions. The long protection cap is also available in plastic.

1.15 Ducts

1.15.1 Plastic duct

Plastic ducts conform to EN 12201-1 and, if not installed in a closed hollow box girder, are resistant to UV radiation. In general, for tendons with a maximum of 12 prestressing steel strands, ducts made of PE 80 or PE 100, class PN 10 may be used, while for larger tendons class PN 6 is sufficient. A frequently used method for jointing is mirror welding.

The minimum wall thicknesses given in Annex 10 are appropriate for the minimal radius and grout or corrosion protection filling material. It is permitted to reduce these values by 15 % for a radius

R 1.5 Rmin. In case of injection of wax as corrosion protection filling material, the values are increased by 15 %, see Annex 10.

1.15.2 Steel duct

Steel ducts conform to EN 10255, EN 10216-1, EN 10217-1, EN 10219-1, or EN 10305-5.

Minimum wall thicknesses of steel ducts are given in Annex 10.

1.16 Material specifications

In Annex 11 the material specifications of the components are given.

1.17 Permanent corrosion protection

In the course of preparing the European Technical Assessment, no characteristic has been assessed for components and materials of the corrosion protection system. In execution, all components or materials are selected according to the standards and regulations in force at the place of use. In the absent of such standards or regulations, components and materials in accordance with ETAG 013, Annex C.1, should be deemed as acceptable.

To protect the tendons from corrosion, ducts, couplers, and anchorages are completely filled with grout according to EN 447 or special grout according to ETAG 013, corrosion protection filling material according ETAG 013, Annex C.4.1 or Annex C.4.2, as applicable at the place of use.



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However, applicable corrosion protection filling materials are grout as rigid material and grease, wax, or an equivalent soft material.

In case of anchorages fully embedded in concrete, the recesses are designed as to permit a reinforced concrete cover with the required dimensions and in any case with a thickness of at least 20 mm. With exposed anchorages or with anchorages with insufficiently thick concrete cover, the surfaces of bearing trumplates and steel caps are provided with corrosion protection.

1.18 Monostrand

Tendons with monostrands are installed in one common duct and grouted prior to stressing.

Monostrand is a prestressing steel strand that is factory-provided with a corrosion protection filling material and an extruded HDPE sheathing. The monostrand conforms to ETAG 013, Annex C1.

The corrosion protection filling material for monostrands is specified in ETAG 013, Annex C.1, or an equivalent soft material. Material and thickness of the sheathing conforms to ETAG 013, Annex C.1.

As an alternative, monostrands, including corrosion protection filling material and sheathing, according to the standards and regulations in force at the place of use may be applied.

2 Specification of the intended uses in accordance with the applicable European Assessment Document (hereinafter EAD)

2.1 Intended uses

The PT system is intended to be used for the prestressing of structures. The specific intended uses are listed in Table 7.

Table 7 Intended uses

Line № Use category

Use categories according to tendon configuration and material of structure

1 External tendon for concrete structures with a tendon path situated outside the cross section of the structure or member but inside its envelope

Optional use categories

2 Restressable external tendon

3 Exchangeable external tendon

4 Electrically isolated tendon

5 Tendon for use in structural composite construction as external tendon

6 Tendon for use in structural masonry construction as external tendon

2.2 Assumptions

2.2.1 General

Concerning product packaging, transport, storage, maintenance, replacement, and repair it is the responsibility of the manufacturer to undertake the appropriate measures and to advise his clients on transport, storage, maintenance, replacement, and repair of the product as he considers necessary.



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2.2.2 Packaging, transport, and storage

Advice on packaging, transport, and storage includes.

During transport of prefabricated tendons, a minimum diameter of curvature of 1.6 m for tendons up to CONA CMI 1506 and 1.70 m for larger tendons is observed.

Temporary protection of prestressing steel and components in order to prevent corrosion during transport from production site to job site

Transportation, storage, and handling of prestressing steel and other components in a manner as to avoid damage by mechanical or chemical impact

Protection of prestressing steel and other components from moisture

Keeping tensile elements separate from areas where welding operations are performed

2.2.3 Design

2.2.3.1 General

Design of the structure permits correct installation and stressing of the tendons. The reinforcement in the anchorage zone permits correct placing and compacting of concrete.

At the anchorages and couplers, the tendon layout provides a straight section over a length as specified in Annex 9 beyond the end of the trumpet.

Couplers are situated in straight tendon sections.

Design of the structure should consider protection of the external tendons against damage by e.g. impact of vehicles, vibrations, etc..

2.2.3.2 Anchorage Recess

Clearance is required for handling of prestressing jacks and for stressing. The dimensions of the anchorage recess are adapted to the prestressing jack used. The ETA holder keeps available information on prestressing jacks and appropriate clearance behind the anchorage.

The anchorage recess is designed with such dimensions as to ensure the required concrete cover and at least 20 mm at the protection cap in the final state.

In case of failure, the bursting out of prestressing steels is prevented. Sufficient protection is provided by e.g. a cover of reinforced concrete.

2.2.3.3 Maximum prestressing force

The prestressing and overstressing forces are specified in the respective standards and regulations in force at the place of use. Annex 15 lists the maximum prestressing and overstressing forces according to Eurocode 2.

2.2.3.4 Centre spacing, edge distance, and reinforcement in the anchorage zone

Centre spacing, edge distance, helix, and additional reinforcement given Annex 16, Annex 17, Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23 are adopted.

Verification of transfer of prestressing forces to structural concrete is not required if centre spacing and edge distances of the tendons as well as grade and dimensions of additional reinforcement, see Annex 16, Annex 17, Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23, are conformed to. In the case of grouped anchorages, the additional reinforcement of the individual anchorages can be combined, provided appropriate anchorage is ensured. However, number, cross-sectional area, and position with respect to the bearing trumplates remains unchanged.

NOTE Centre spacing and edge distances as well as concrete strength and reinforcement for larger tendons in terms of number, nominal diameter, and strength of prestressing steel strands are as well applicable to smaller tendons. For example, it is fully applicable to fit a



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tendon CONA CME 1906-140 1860 into an anchorage zone, detailed and executed for a CONA CME 2406-150 1860 tendon.

The reinforcement of the structure is not employed as additional reinforcement. Reinforcement exceeding the required reinforcement of the structure may be used as additional reinforcement, provided appropriate placing is possible.

The forces outside the area of the additional reinforcement are verified and, if necessary, dealt with by appropriate reinforcement.

If required for a specific project design, the reinforcement given in Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23 may be modified in accordance with the respective regulations in force at the place of use as well as with the relevant approval of the local authority and of the ETA holder to provide equivalent performance.

2.2.3.5 Fixed coupler

The prestressing force at the second construction stage is at no time greater than at the first construction stage, neither during construction, nor in the final state, nor due to any load combination.

2.2.3.6 Tendons in masonry structures – Load transfer to the structure

Load transfer of prestressing force to masonry structures is via concrete or steel members, designed according to the European Technical Assessment, in particular according to the Clauses 1.9, 1.11, 1.14.8, and 2.2.3.4 or according to Eurocode 3 respectively.

The concrete or steel members have such dimensions as to permit a force of 1.1 · Fpk being transferred into the masonry. The verification is performed according to Eurocode 6 as well as to the respective standards and regulations in force at the place of use.

Deviators are made of concrete or steel. The transfer of the forces from the deviator to the masonry is verified according to Eurocode 6 as well as to the respective standards and regulations in force at the place of use.

2.2.4 Installation

2.2.4.1 General

Assembly and installation of tendons are only carried out by qualified PT specialist companies with the required resources and experience in the use of external multi strand post-tensioning systems, see ETAG 013, Annex D.1 and CWA 14646. The respective standards and regulations in force at the place of use are considered. The company's PT site manager has a certificate, stating that she or he has been trained by the ETA holder and that she or he possesses the necessary qualifications and experience with the external PT system BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands.

The tendons may be manufactured on site or in the factory – prefabricated tendons.

Bearing trumplate, anchor head, and coupler anchor head are placed perpendicular to the tendon's axis.

Installation is carried out according to Annex 25, Annex 26, Annex 27, and Annex 28.

In case of single plane coupler K, the prestressing steel strands are provided with markers to be able to check the depth of engagement.

2.2.4.2 Monostrand tendons

The monostrands are threaded in one common duct, see Annex 26.

Prior to stressing, the monostrand tendon is grouted.

After grouting, the sealing plate and activation plate are removed. The protruding monostrands are de-sheathed and the anchor head A is placed for stressing.



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Stressing can be commenced, once compressive strength of the grout is sufficiently developed.

This is in general not before a compressive strength of 10 MPa is attained by the grout.

After stressing, protection cap A is fastened with screws on the anchorage. Protection cap A encases the anchorage and is filled with corrosion protection filling material to complete the corrosion protection. After filling, the inlet port of protection cap A is sealed with a plug.

2.2.4.3 Electrically isolated tendon

For electrical isolation, isolation ring E together with steel ring E are placed between bearing trumplate E and anchor head A, see Annex 2. Trumpet E and inner trumpet E extend through bearing trumplate E. Steel ring E is screwed on trumpet E or inner trumpet E

Voids in bearing trumplate E are filled with polymeric material to enhance electrical isolation.

After stressing, protection cap E is fastened with screws on the anchorage. Protection cap E encases the anchorage and provides a port as inlet or vent. After filling, all inlet and outlet ports of the electrically isolated tendon are sealed with suitable plugs to provide fully electrical isolation.

With electrically isolated tendon, the complete tendon, i.e. including prestressing steel strands, anchorages, and couplers, is fully encased with isolation material. The integrity of the electrical isolation is verified via electrical resistance measurements between tendon and reinforcement of the structure.

2.2.4.4 Stressing operation

With a mean concrete compressive strength in the anchorage zone according to the values laid down in Annex 18, Annex 19, Annex 20, Annex 21, Annex 22, and Annex 23 full prestressing may be applied.

Stressing and, if applicable, wedging is carried out using a suitable prestressing jack. The wedging force corresponds to approximately 25 kN per wedge.

Elongation and prestressing forces are continuously checked during the stressing operation. The results of the stressing operation are recorded and the measured elongations compared with the prior calculated values.

After releasing the prestressing force from the prestressing jack, the tendon pulls the prestressing steel strands by the amount of the slip into the anchor head.

Information on the prestressing equipment has been submitted to Österreichisches Institut für Bautechnik. The ETA holder keeps available information on prestressing jacks and appropriate clearance behind the anchorage.

The safety-at-work and health protection regulations shall be complied with.

2.2.4.5 Restressing

Restressing of tendons in combination with release and reuse of wedges is permitted, whereas the wedges bite into a least 15 mm of virgin strand surface and no wedge bite remains inside the final length of the tendon between anchorages.

For tendons remaining restressable throughout the working life of the structure, soft corrosion protection filling material according to Clause 1.17 is used. Moreover, a strand protrusion at the stressing anchor remains with a length, compatible with the prestressing jack used. The protruding prestressing steel strands are provided with an appropriate corrosion protection and a long protection cap is attached to the anchorage, see Annex 1.



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2.2.4.6 Filling operations

2.2.4.6.1 Grouting

Grouting accessories such as inlets, outlets, caps, vents, etc. require compatibility with the PT system and provide sufficient tightness. Protection caps are always used to ensure proper grouting of tendon and to avoid voids around the wedges. Grout is injected through the inlet holes until it escapes from the outlet tubes with the same consistency. To avoid voids in the hardened grout special measures are applied for long tendons, tendon paths with distinct high points or inclined tendons. All vents and grouting inlets are sealed immediately after grouting. In case of K-couplers, the holes of the second construction stage, together with wedges and springs are checked for cleanness before and immediately after grouting the first construction stage.

The standards, observed for cement grouting in prestressing ducts, are EN 445, EN 446, and EN 447 or the standards and regulations in force at the place of use applies for ready mixed grout.

The results of the grouting operation are recorded in the grouting records.

2.2.4.6.2 Filling with corrosion protection filling material

The specifications in ETAG 013, Annex C.4, and the recommendations of the supplier are relevant for corrosion protection filling material.

Filling with corrosion protection filling material follows a similar procedure as the one specified for grouting.

The results of the filling operation are recorded in the filling records.

2.2.4.7 Exchange of tendons

Specifications for exchangeable tendons are defined during the design phase. Subject of exchange is either

The prestressing steel strands either the complete tendon or stand by strand

The complete tendon including prestressing steel strands, duct, and inner trumpet

Unless special procedures are considered already in the design phase of the structure, strand protrusions remain at the stressing anchor with a length compatible with the prestressing jack and allowing for release of the complete prestressing force. Moreover, soft corrosion protection filling material according to Clause 1.17 is applied.

Tendons with bare strands, grouted in a common duct, can only be completely removed and subsequently replaced by a new tendon. After full release of the prestressing force, the complete tendon with inner trumpet A is pulled out from the structure and replaced by a new tendon.

Stressing and fixed anchorages are accessible and adequate space is provided behind the anchorages.

2.2.4.8 Welding

Ducts may be welded.

The helix may be welded to the bearing trumplate to secure its position.

After installation of the tendons, no further welding operations are carried out on the tendons. In case of welding operations near tendons, precautionary measures are required to avoid damage.

Plastic components may be welded even after installation of the tendons.



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2.3 Assumed working life

The European Technical Assessment is based on an assumed working life of the BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands of 100 years, provided that the BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands is subject to appropriate installation, use, and maintenance, see Clause 2.2. These provisions are based upon the current state of the art and the available knowledge and experience.

In normal use conditions, the real working life may be considerably longer without major degradation affecting the basic requirements for construction works4.

The indications given as to the working life of the construction product cannot be interpreted as a guarantee, neither given by the product manufacturer or his representative nor by EOTA nor by the Technical Assessment Body, but are regarded only as a means for expressing the expected economically reasonable working life of the product.

3 Performance of the product and references to the methods used for its assessment

3.1 Essential characteristics

The performances of the PT system for the essential characteristics are given in Table 8 and Table 9. In Annex 31 the combinations of essential characteristics and corresponding intended uses are listed.

Table 8 Essential characteristics and performances of the product

№ Essential characteristic Product performance

Product

BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands

Intended use

The PT system is intended to be used for the prestressing of structures, Clause 2.1, Table 7, line № 1

Basic requirement for construction works 1: Mechanical resistance and stability

1 Resistance to static load See Clause 3.2.1.1.

2 Resistance to fatigue See Clause 3.2.1.2.

3 Load transfer to the structure See Clause 3.2.1.3.

4 Friction coefficient See Clause 3.2.1.4.

5 Deviation, deflection (limits) See Clause 3.2.1.5.

6 Practicability, reliability of installation See Clause 3.2.1.6.

Basic requirement for construction works 2: Safety in case of fire

Not relevant. No characteristic assessed.

4 The real working life of a product incorporated in a specific works depends on the environmental conditions to

which that works are subject, as well as on the particular conditions of design, execution, use, and maintenance of that works. Therefore, it cannot be excluded that in certain cases the real working life of the product may also be shorter than the assumed working life.



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№ Essential characteristic Product performance

Basic requirement for construction works 3: Hygiene, health, and the environment

7 Content, emission, and/or release of dangerous substances

See Clause 3.2.2.

Basic requirement for construction works 4: Safety and accessibility in use


Basic requirement for construction works 5: Protection against noise


Basic requirement for construction works 6: Energy economy and heat retention


Basic requirement for construction works 7: Sustainable use of natural resources

No characteristic assessed.

Related aspects of serviceability

8 Related aspects of serviceability See Clause 3.2.3.

Table 9 Essential characteristics and performances of the product in addition to Table 8 for optional use categories

№ Additional essential characteristic Product performance

Product


Optional use category

Clause 2.1, Table 7, lines № 2, Restressable external tendon



Product



Clause 2.1, Table 7, lines № 3, Exchangeable external tendon





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№ Additional essential characteristic Product performance

Product



Clause 2.1, Table 7, lines № 4, Electrically isolated tendon



Product



Clause 2.1, Table 7, lines № 5, Tendon for use in structural composite construction as external tendon



Product



Clause 2.1, Table 7, lines № 6, Tendon for use in structural masonry construction as external tendon



3.2 Product performance

3.2.1 Mechanical resistance and stability

3.2.1.1 Resistance to static load

The PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.1-I. The characteristic values of maximum force, Fpk, of tendons with prestressing steel strands according to Annex 12 are listed in Annex 13 and Annex 14.

3.2.1.2 Resistance to fatigue


3.2.1.3 Load transfer to the structure




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3.2.1.4 Friction coefficient

The PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.4-I. For friction losses including friction coefficient see Clause 1.7.

3.2.1.5 Deviation, deflection (limits)

The PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.5-I. For minimum radii of curvature, see Clause 1.10.

3.2.1.6 Practicability, reliability of installation

The PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.6-I.

3.2.2 Hygiene, health, and the environment

Content, emission, and/or release of dangerous substances is determined according to ETAG 013, Clause 5.3.1. No dangerous substances is the performance of the PT system in this respect. A manufacturer’s declaration to this effect has been submitted.

NOTE In addition to specific clauses relating to dangerous substances in the European Technical Assessment, there may be other requirements applicable to the product falling within their scope, e.g. transposed European legislation and national laws, regulations and administrative provisions. These requirements also need to be complied with, when and where they apply.

3.2.3 Related aspects of serviceability

The PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.7.

3.2.4 Mechanical resistance and stability

3.2.4.1 Restressable external tendon – Practicability, reliability of installation

For restressable tendons, the PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.6-II(a).

3.2.4.2 Exchangeable external tendon – Practicability, reliability of installation

For exchangeable tendons, the PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.6-II(b).

3.2.4.3 Electrically isolated tendon – Practicability, reliability of installation

For electrically isolated tendons, the PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.6-II(f).

3.2.4.4 Tendons in masonry structures – Load transfer to the structure

For tendons for use in structural masonry construction as external tendons, the PT system as described in the ETA meets the acceptance criteria of ETAG 013, Clause 6.1.3-II(h). See in particular Clause 2.2.3.6 for tendons in masonry structures. The characteristic values of maximum force, Fpk, of tendons with prestressing steel strands according to Annex 12 are listed in Annex 13 and Annex 14.

3.3 Assessment methods

The assessment of the essential characteristics in Clause 3.1 of the PT system for the intended uses and in relation to the requirements for mechanical resistance and stability, and for hygiene, health, and the environment in the sense of the basic requirements for construction works № 1 and 3 of Regulation (EU) № 305/2011 has been made in accordance with the Guideline for European technical approvals of “Post-Tensioning Kits for Prestressing of Structures”, ETAG 013, edition



OIB-205-058/17-021

June 2002, used according to Article 66 (3) of Regulation (EU) № 305/2011 as European Assessment Document, and is based on the assessment for external PT systems.

3.4 Identification

The European Technical Assessment for the PT system is issued on the basis of agreed data5 that identify the assessed product. Changes to materials, to composition, to characteristics of the product, or to the production process could result in these deposited data being incorrect. Österreichisches Institut für Bautechnik should be notified before the changes are introduced, as an amendment of the European Technical Assessment is possibly necessary.

4 Assessment and verification of constancy of performance (hereinafter AVCP) system applied, with reference to its legal base

4.1 System of assessment and verification of constancy of performance

According to Commission Decision 98/456/EC, the system of assessment and verification of constancy of performance to be applied to the PT system is System 1+. System 1+ is detailed in Commission Delegated Regulation (EU) № 568/2014 of 18 February 2014, Annex, point 1.1., and provides for the following items.

(a) The manufacturer shall carry out

(i) factory production control;

(ii) further testing of samples taken at the manufacturing plant by the manufacturer in accordance with the prescribed test plan6.

(b) The notified product certification body shall decide on the issuing, restriction, suspension, or withdrawal of the certificate of constancy of performance of the construction product on the basis of the outcome of the following assessments and verifications carried out by that body

(i) an assessment of the performance of the construction product carried out on the basis of testing (including sampling), calculation, tabulated values, or descriptive documentation of the product;

(ii) initial inspection of the manufacturing plant and of factory production control;

(iii) continuing surveillance, assessment, and evaluation of factory production control;

(iv) audit-testing of samples taken by the notified product certification body at the manufacturing plant or at the manufacturer's storage facilities.

4.2 AVCP for construction products for which a European Technical Assessment has been issued

Notified bodies undertaking tasks under System 1+ shall consider the European Technical Assessment issued for the construction product in question as the assessment of the performance of that product. Notified bodies shall therefore not undertake the tasks referred to in Clause 4.1, point (b) (i).

5 The technical file of the European Technical Assessment is deposited at Österreichisches Institut für

Bautechnik. 6 The prescribed test plan has been deposited with Österreichisches Institut für Bautechnik and is handed over

only to the notified product certification body involved in the procedure for the assessment and verification of constancy of performance. The prescribed test plan is also referred to as control plan.



OIB-205-058/17-021

5 Technical details necessary for the implementation of the AVCP system, as provided for in the applicable EAD

5.1 Tasks for the manufacturer

5.1.1 Factory production control

In the manufacturing plant, the manufacturer establishes and continuously maintains a factory production control. All procedures and specifications adopted by the manufacturer are documented in a systematic manner. Purpose of factory production control is to ensure the constancy of performances of the BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands with regard to the essential characteristics.

The manufacturer only uses raw materials supplied with the relevant inspection documents as laid down in the control plan. The incoming raw materials are subjected to controls by the manufacturer before acceptance. Check of incoming materials includes control of inspection documents presented by the manufacturer of the raw materials.

Testing within factory production control is in accordance with the prescribed test plan. The results of factory production control are recorded and evaluated. The records are presented to the notified product certification body involved in continuous surveillance and are kept at least for ten years after the product has been placed on the market. On request, the records are presented to Österreichisches Institut für Bautechnik.

If test results are unsatisfactory, the manufacturer immediately implements measures to eliminate the defects. Products or components that are not in conformity with the requirements are removed. After elimination of the defects, the respective test – if verification is required for technical reasons – is repeated immediately.

At least once a year the manufacturer audits the manufacturers of the components given in Annex 30.

The basic elements of the prescribed test plan are given in Annex 29, conform to ETAG 013, Annex E.1, and are specified in the quality management plan of the BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands.

5.1.2 Declaration of performance

The manufacturer is responsible for preparing the declaration of performance. When all the criteria of the assessment and verification of constancy of performance are met, including the certificate of constancy of performance issued by the notified product certification body, the manufacturer draws up the declaration of performance. Essential characteristics included in the declaration of performance for the corresponding intended use are given in Table 8 and Table 9. In Annex 31 the combinations of essential characteristics and corresponding intended uses are listed.

5.2 Tasks for the notified product certification body

5.2.1 Initial inspection of the manufacturing plant and of factory production control

The notified product certification body verifies the ability of the manufacturer for a continuous and orderly manufacturing of the BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands according to the European Technical Assessment. In particular, the following items are appropriately considered.

Personnel and equipment

Suitability of the factory production control established by the manufacturer

Full implementation of the prescribed test plan



OIB-205-058/17-021

5.2.2 Continuing surveillance, assessment, and evaluation of factory production control

The notified product certification body visits the factory at least once a year for routine inspection. In particular the following items are appropriately considered.

Manufacturing process including personnel and equipment

Factory production control

Implementation of the prescribed test plan

Each manufacturer of the components given in Annex 30 is audited at least once in five years. It is verified that the system of factory production control and the specified manufacturing process are maintained, taking account of the prescribed test plan.

The results of continuous surveillance are made available on demand by the notified product certification body to Österreichisches Institut für Bautechnik. When the provisions of the European Technical Assessment and the prescribed test plan are no longer fulfilled, the certificate of constancy of performance is withdrawn by the notified product certification body.

5.2.3 Audit-testing of samples taken by the notified product certification body at the manufacturing plant or at the manufacturer's storage facilities

During surveillance inspections, the notified product certification body takes samples of components of the BBR VT CONA CME – External Post-tensioning System with 04 to 61 Strands for independent testing. For the most important components, Annex 30 summarises the minimum procedures performed by the notified product certification body.

Issued in Vienna on 18 December 2017 by Österreichisches Institut für Bautechnik

The original document is signed by

Rainer Mikulits Managing Director



OIB-205-058/17-021

Stressing anchorage, accessible fixed anchorage SA, FA

Inaccessible fixed anchorage FA

Fixed coupler FK

Fixed coupler FH

Restressable anchorage

CONA CME


Overview on anchorages and couplers

Annex 1

of European Technical Assessment

ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Stressing anchorage, accessible fixed anchorage, replaceable SAR

Electrically isolated stressing, accessible fixed anchorage SAE

Electrically isolated inaccessible fixed anchorage FAE

Electrically isolated, stressing, accessible fixed anchorage, replaceable SAER

Electrically isolated fixed and stressing coupler FHE, SHE

CONA CME


Overview on anchorages and couplers

Annex 2


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Anchor head A1–A4 Cone A1–A4

A

HAA1 A2

A

HAA3 A4 Ø

27.3

Anchor head A5–A8 Cone A5–A8

A

HAA5 A6

A

HAA7 A8

Ø 2

7.3

Coupler head K

K

HK

Cover plate K

D

DD

Spring A

22

45

Spring K

27

37

Ring cushion Anchor head A5–A8

20

Wedge

H

~ 1.5

F

~ 1.5

Z

~ 1.8

28

45

Dimensions in mm

Number of strands 04 07 09 12 15 19 22 24 27 31 37 42 43 48 55 61

Anchor head A

Diameter A mm 100 130 160 160 200 200 225 240 255 255 285 300 320 325 335 365

Height head A1–A4 HA

mm 50 55 60 65 75 85 95 100 105 110

Height head A5–A8 mm 65 65 65 70 75 85 95 100 105 110 120 130 130 140 150 155

Coupler head K

Diameter K mm 195 210 250 250 290 290 310 340 390 390

Height HK mm 85 85 90 90 90 95 105 120 125 130

Cover plate

Diameter D mm 182 207 246 246 286 286 306 336 386 386

Thickness DD mm 3 3 3 3 3 3 5 5 5 5

CONA CME


Components – Anchorage and coupler

Annex 3


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Bearing trumplate A

B

HB

Coupler sleeve H

H

LH

Coupler head H1

A

H

HAH

Coupler head H2

A

H

HAH

Wedge retaining plate H

K

S

DKS

Wedge retaining plate A

K

S

DKS


Bearing trumplate A

Diameter P mm 130 170 225 225 280 280 310 325 360 360 400 425 485 485 485 520

Height HP mm 120 128 150 150 195 195 206 227 250 250 275 290 340 340 340 350

Coupler head H1 and H2

Nominal diameter AH mm 100 130 160 160 200 200 225 240 255 255 285 300 320 325 335 365

Height head H1 HAH

mm 55 65 70 80 80 95 100 100 105 115

Height head H2 mm 55 65 70 80 80 95 100 100 105 115 125 135 135 145 160 160

Coupler sleeve H

Minimum diameter H mm 130 170 203 213 259 269 296 312 330 338 370 392 410 422 440 472

Length LH mm 180 200 210 230 240 270 270 280 300 320 320 340 360 380 410 410

Wedge retaining plate A

Diameter KS mm 75 103 145 145 175 175 182 210 210 210 240 275 275 275 310 310

Thickness DKS mm 5 5 8 8 10 10 10 10 10 10 12 12 12 12 12 12

Wedge retaining plate H

Diameter KS mm 75 103 145 145 175 175 182 210 210 210 240 275 275 275 310 310

Thickness DKS mm 10 10 12 12 15 15 15 15 15 15 15 15 15 15 15 15

CONA CME


Components – Anchorage and coupler

Annex 4


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Trumpet A

T

A

LTA

Trumpet K Tension Ring

T

K

LTK

T

R

LTR

Trumpet H PE-Insert

T

H

LTH

I

LI


Trumpet A

Diameter TA mm 72 88 127 127 153 153 170 191 191 191 219 229 254 254 254 278

Length LTA mm 200 328 623 508 694 579 715 866 866 751 1 060 1 244 1 290

Tension ring

Diameter TR mm 130 150 150 165 200 200 215 215 215 230 250 250 250 270 270 290

Length LTR mm 95 95 135 135 168 168 168 168 168 168 168 168 168 168 168 168

PE-Insert

Diameter I mm 105 105 105 120 150 150 165 165 165 180 200 200 200 220 220 240

Length LI mm 110 110 150 150 220 220 220 220 220 220 220 220 220 220 220 220

Trumpet H

Diameter TH mm 170 203 213 259 269 296 312 330 338 370 392 410 422 440 472

Length LTH mm 190 570 390 480 480 550 820 820 660 930 890 1 080 910 980 1 070

Trumpet K

Diameter TK mm 195 210 250 250 290 290 310 340 390 390

Length LTK mm 308 340 428 428 473 473 498 597 734 734

CONA CME


Components – Accessory

Annex 5


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Temporary sealing plate Activation plate

T

SHTS

A

P

HAP

Protection cap A

P

C

HPC

Long protection cap

Am

in

Hmin Fmin

Jm

in


Temporary sealing plate

Diameter TS mm 129 169 225 225 260 260 290 305 330 330 380 405 465 465 465 500

Height HTS mm 29 29 29 29 30 30 30 30 30 30 30 35 40 40 40 40

Activation plate

Diameter AP mm 90 120 150 150 180 180 200 220 220 220 265 280 300 300 315 345

Height HAP mm 10 10 15 15 15 15 15 15 15 15 15 15 15 15 15 15

Protection cap A

Diameter PC mm 116 146 218 218 260 260 290 305 320 320 360 380 400 400 400 440

Height HPC mm 98 106 108 108 128 128 141 143 158 158 175 190 190 200 210 210

Long protection cap in steel

Minimum diameter Amin mm 110 140 170 170 210 210 240 250 270 270 300 310 330 340 350 370

Minimum wall thickness Jmin mm 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

Minimum cover thickness Fmin mm 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5 5

NOTES Hmin depends on the required excess length for the jack. Long protection cap in plastic are with adapted dimensions for Jmin and Fmin.

CONA CME



Annex 6


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Trumpet E

T

E

LTE

Steel ring E Bearing trumplate E

R

HR

B

E

HBE

Protection cap E Isolation ring E

P

E

HPE

Number of strands 04 07 09 12 15 19 22 24 27 31

Trumpet E

Diameter TE mm 74 93 128 128 157 157 178 191 201 201

Length LTE mm 312 428 600 600 848 848 980 1 005 1 040 1 040

Steel ring E

Diameter R mm 100 130 173 173 220 220 244 256 279 279

Height HR mm 59 59 65 65 65 65 65 65 65 65

Bearing trumplate E

Diameter BE mm 130 170 225 225 280 280 310 325 360 360

Height HBE mm 120 128 150 150 195 195 206 227 250 250

Protection Cap E

Diameter PE mm 143 168 229 229 276 276 306 316 348 348

Height HPE mm 167 174 185 185 205 205 219 223 233 233

CONA CME


Electrically isolated tendon Components – Anchorage and accessory

Annex 7


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Inner trumpet A

IT

A

LITA

Inner trumpet E

IT

E

LITE


Inner trumpet A

Diameter ITA mm 69 89 126 126 159 159 179 194 204 204 224 238 264 264 264 296

Length LITA mm 190 220 620 538 654 654 640 910 910 755 1 020 980 1 170 995 1 070 1 160

Inner trumpet E

Diameter ITE mm 74 93 128 128 156 156 178 191 201 201

Length LITE mm 220 250 650 568 684 684 670 940 940 785

CONA CME



Annex 8


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Straight length at fixed and stressing anchorage

Lmin

Degree of filling 0.35 f 0.50, minimum straight length Lmin = 5 ∙ di 250 mm

Degree of filling 0.25 f 0.30, minimum straight length Lmin = 8 ∙ di 400 mm

Where

f......................... Degree of filling, see Clause 1.6 di.........mm............ Nominal inner diameter of duct

Deviator

Venting port

(If required)

Pre-installed duct

Recess unit

α

Venting port

(If required)

Recess unitα

Key

R1 R2 Rmin Δα Additional deviation, e. g. 3 ° For Rmin see Annex 10.

CONA CME


Deviator and straight length

Annex 9


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Duct


Bare strand

PE

Duct Minimum radii of

curvature Rmin m 2.0 2.0 2.2 2.5 2.7 3.0 3.2 3.3 3.5 3.7 4.0 4.5 4.5 4.5 5.2 5.5

Diameter da mm 50 75 75 90 110 110 125 125 125 140 140 160 160 180 180 200

Thickness t mm 3.7 5.6 5.6 5.4 5.3 5.3 6.0 6.0 6.0 6.7 6.7 7.7 7.7 8.6 8.6 9.6

PE


curvature 1.5 Rmin m 3.0 3.0 3.3 3.8 4.1 4.5 4.8 5.0 5.3 5.6 6.0 6.8 6.8 6.8 7.8 8.3

Diameter da mm 63 75 75 90 110 110 125 125 125 140 140 160 160 180 180 200

Thickness t mm 2.4 4.5 4.5 4.3 4.2 4.2 4.8 4.8 4.8 6.7 5.4 6.2 6.2 6.9 6.9 7.7

Ste

el d

uct Minimum radii of

curvature Rmin m 2.0 2.0 2.2 2.5 2.7 3.0 3.2 3.3 3.5 3.7 4.0 4.5 4.5 4.5 5.2 5.5

Diameter da mm 48 64 73 83 89 102 114 114 127 127 141 168 168 168 168 168

Thickness t mm 1.5 1.5 1.5 1.5 2.0 2.0 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.0 3.0 3.0

Monostrand

PE


curvature Rmin m 2.0 2.0 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

Diameter da mm 75 90 90 110 125 125 140 140 140 160 180 180 180 200 225 225

Thickness t mm 5.6 5.4 5.4 5.3 5.3 5.3 5.4 5.4 5.4 6.2 6.9 6.9 6.9 7.7 8.6 8.6

Ste

el d

uct Minimum radii of

curvature Rmin m 2.0 2.0 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5 2.5

Diameter da mm 57 76 83 95 114 114 127 140 152 159 168 178 178 194 219 219

Thickness t mm 1.5 1.5 1.5 1.5 2.0 2.0 2.0 2.0 2.5 2.5 2.5 3.0 3.0 3.0 3.0 3.0

CONA CME


Duct

Annex 10


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Material specifications

Component Standard / Specification

Anchor head A CONA CME 0406 to 6106

EN 10083-1 EN 10083-2

Coupler anchor head K CONA CME 0406 to 3106

EN 10083-1 EN 10083-2

Coupler anchor head H CONA CME 0406 to 6106

EN 10083-1 EN 10083-2

Bearing trumplate A CONA CME 0406 to 6106

EN 1561 EN 1563

Bearing trumplate E CONA CME 0406 to 3106

EN 1561 EN 1563

Coupler sleeve H CONA CME 0406 to 6106

EN 10210-1

Wedge retaining plate A and H CONA CME 0406 to 6106

EN 10025-2

Cover plate K CONA CME 0406 to 3106

EN 10025-2

Trumpet A, K, and E EN ISO 17855-1 EN ISO 19069-1

Trumpet A and K EN 10025

Steel ring E EN 10210-1

Isolation ring E Composite material

Ring cushion EN ISO 17855-1 EN ISO 19069-1

Protection cap A Protection cap E Long protection cap

EN ISO 17855-1

Protection cap A Long protection cap

EN 10025

Tension ring EN 10210-1

Ring wedge H, F, and Z EN 10277-2 EN 10084

Spring A, K EN 10270-1

Helix Ribbed reinforcing steel, Re 500 MPa

Additional reinforcement, stirrups Ribbed reinforcing steel, Re 500 MPa

Duct EN 10210-1 ETAG 013, Annex C.2

CONA CME


Material specifications

Annex 11


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

7-wire strands according to prEN 10138-3 1)

Steel designation Y1770S7 Y1860S7 Y1770S7 Y1860S7

Tensile strength Rm MPa 1 770 1 860 1 770 1 860

Diameter d mm 15.3 15.3 15.7 15.7

Nominal cross-sectional area Ap mm2 140 140 150 150

Nominal mass per metre m kg/m 1.093 1.172

Permitted deviation from nominal mass % 2

Characteristic value of maximum force

Fpk kN 248 260 266 279

Maximum value of maximum force Fm, max kN 285 299 306 321

Characteristic value of 0.1 % proof force 2)

Fp0.1 kN 218 229 234 246

Minimum elongation at maximum

force, L0 500 mm Agt % 3.5

Modulus of elasticity Ep MPa 195 000 3)

1) Suitable strands according to standards and regulations in force for at the place of use may also be used. 2) For strands according to prEN 10138-3, 09.2000, the values are multiplied by 0.98. 3) Standard value

CONA CME


Strand specifications

Annex 12


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

CONA CME n06-140

Number of strands

Nominal cross-sectional area of prestressing steel

Nominal mass of prestressing steel

Characteristic value of maximum force of tendon

fpk = 1 770 MPa fpk = 1 860 MPa

n Ap M Fpk Fpk

mm2 kg/m kN kN

04 560 4.4 992 1 040

07 980 7.7 1 736 1 820

09 1 260 9.8 2 232 2 340

12 1 680 13.1 2 976 3 120

15 2 100 16.4 3 720 3 900

19 2 660 20.8 4 712 4 940

22 3 080 24.0 5 456 5 720

24 3 360 26.2 5 952 6 240

27 3 780 29.5 6 696 7 020

31 4 340 33.9 7 688 8 060

37 5 180 40.4 9 176 9 620

42 5 880 45.9 10 416 10 920

43 6 020 47.0 10 664 11 180

48 6 720 52.5 11 904 12 480

55 7 700 60.1 13 640 14 300

61 8 540 66.7 15 128 15 860

CONA CME


Tendon ranges

Annex 13


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

CONA CME n06-150

Number of strands

Nominal cross-sectional area of prestressing steel

Nominal mass of prestressing steel

Characteristic value of maximum force of tendon

fpk = 1 770 MPa fpk = 1 860 MPa

n Ap M Fpk Fpk

mm2 kg/m kN kN

04 600 4.7 1 064 1 116

07 1 050 8.2 1 862 1 953

09 1 350 10.5 2 394 2 511

12 1 800 14.1 3 192 3 348

15 2 250 17.6 3 990 4 185

19 2 850 22.3 5 054 5 301

22 3 300 25.8 5 852 6 138

24 3 600 28.1 6 384 6 696

27 4 050 31.6 7 182 7 533

31 4 650 36.3 8 246 8 649

37 5 550 43.4 9 842 10 323

42 6 300 49.2 11 172 11 718

43 6 450 50.4 11 438 11 997

48 7 200 56.3 12 768 13 392

55 8 250 64.5 14 630 15 345

61 9 150 71.5 16 226 17 019

CONA CME


Tendon ranges

Annex 14


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Maximum prestressing and overstressing forces

Designation CONA CME

n06-140 n06-150 n06-140 n06-150

Maximum prestressing force 1)

0.9 · Fp0.1 Maximum overstressing force 1), 2)

0.95 · Fp0.1

Characteristic tensile strength fpk

MPa 1 770 1 860 1 770 1 860 1 770 1 860 1 770 1 860

kN kN kN kN kN kN kN kN

n

Number of strands

04 785 824 842 886 828 870 889 935

07 1 373 1 443 1 474 1 550 1 450 1 523 1 556 1 636

09 1 766 1 855 1 895 1 993 1 864 1 958 2 001 2 103

12 2 354 2 473 2 527 2 657 2 485 2 611 2 668 2 804

15 2 943 3 092 3 159 3 321 3 107 3 263 3 335 3 506

19 3 728 3 916 4 001 4 207 3 935 4 133 4 224 4 440

22 4 316 4 534 4 633 4 871 4 556 4 786 4 891 5 141

24 4 709 4 946 5 054 5 314 4 970 5 221 5 335 5 609

27 5 297 5 565 5 686 5 978 5 592 5 874 6 002 6 310

31 6 082 6 389 6 529 6 863 6 420 6 744 6 891 7 245

37 7 259 7 626 7 792 8 192 7 663 8 049 8 225 8 647

42 8 240 8 656 8 845 9 299 8 698 9 137 9 337 9 815

43 8 437 8 862 9 056 9 520 8 905 9 355 9 559 10 049

48 9 418 9 893 10 109 10 627 9 941 10 442 10 670 11 218

55 10 791 11 336 11 583 12 177 11 391 11 965 12 227 12 854

61 11 968 12 572 12 847 13 505 12 633 13 271 13 560 14 256

1) The given values are maximum values according to Eurocode 2. The actual values are taken from the standards and regulations in force at the place of use. Conformity with the stabilisation and crack width

criteria in the load transfer test was verified to a load level of 0.80 Fpk

2) Overstressing is permitted if the force in the prestressing jack can be measured to an accuracy of 5 % of the final value of the overstressing force.

CONA CME


Maximum prestressing and overstressing forces

Annex 15


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Minimum centre spacing of tendon anchorages

Tendon Minimum centre spacing ac = bc

fcm, 0, cube, 150 MPa 23 28 34 38 43

fcm, 0, cylinder, 150 MPa 19 23 28 31 35

CONA CME 0406 mm 235 215 210 210 205

CONA CME 0706 mm 310 285 260 255 255

CONA CME 0906 mm 350 320 310 310 310

CONA CME 1206 mm 405 370 340 325 310

CONA CME 1506 mm 455 415 380 365 365

CONA CME 1906 mm 510 465 425 410 390

CONA CME 2206 mm 550 500 460 440 420

CONA CME 2406 mm 575 525 480 460 435

CONA CME 2706 mm 610 555 505 485 460

CONA CME 3106 mm 650 595 545 520 495

CONA CME 3706 mm 680 680 680 680

CONA CME 4206 mm 735 735 735 735

CONA CME 4306 mm 755 755 755 755

CONA CME 4806 mm 805 805 805 805

CONA CME 5506 mm 875 875 875 875

CONA CME 6106 mm 940 940 940 940

CONA CME


Minimum centre spacing

Annex 16


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Minimum edge distance of tendon anchorages

Tendon Minimum edge distance ae = be

fcm, 0, cube, 150 MPa 23 28 34 38 43

fcm, 0, cylinder, 150 MPa 19 23 28 31 35

CONA CME 0406 mm 110 + c 100 + c 95 + c 95 + c 95 + c

CONA CME 0706 mm 145 + c 135 + c 120 + c 120 + c 120 + c

CONA CME 0906 mm 165 + c 150 + c 145 + c 145 + c 145 + c

CONA CME 1206 mm 195 + c 175 + c 160 + c 155 + c 145 + c

CONA CME 1506 mm 220 + c 200 + c 180 + c 175 + c 175 + c

CONA CME 1906 mm 245 + c 225 + c 205 + c 195 + c 185 + c

CONA CME 2206 mm 265 + c 240 + c 220 + c 210 + c 200 + c

CONA CME 2406 mm 280 + c 255 + c 230 + c 220 + c 210 + c

CONA CME 2706 mm 295 + c 270 + c 245 + c 235 + c 220 + c

CONA CME 3106 mm 315 + c 290 + c 265 + c 250 + c 240 + c

CONA CME 3706 mm 330 + c 330 + c 330 + c 330 + c

CONA CME 4206 mm 360 + c 360 + c 360 + c 360 + c

CONA CME 4306 mm 370 + c 370 + c 370 + c 370 + c

CONA CME 4806 mm 395 + c 395 + c 395 + c 395 + c

CONA CME 5506 mm 430 + c 430 + c 430 + c 430 + c

CONA CME 6106 mm 460 + c 460 + c 460 + c 460 + c

c .... Concrete cover in mm

Standards and regulations on concrete cover in force at the place of use are observed.

CONA CME


Minimum edge distance

Annex 17


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Stressing and fixed anchorage or coupler

Centre spacing and edge distance

B

B F

E

ca'e a'e

ae ae

c

be

bc

c a'e

ae ac

c

be

bc

b' e

b' e

c

ae = a'e + c be = b'e + c c … Concrete cover

Technical data of anchorages

BBR VT CONA CME 04 07 09

Strand arrangement

Strand 1) mm2 150 150 150

Cross-sectional area mm2 600 1 050 1 350

Charact. tensile strength

Rm MPa 1 860 1 860 1 860

Charact. maximum force Fm kN 1 116 1 953 2 511

0.90 · Fp0.1 kN 886 1 550 1 993

0.95 · Fp0.1 kN 935 1 636 2 103

Helix and additional reinforcement

Min. concrete strength, cube

fcm, 0 MPa 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43

Min. concrete strength, cylinder

fcm, 0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

Helix

Outer diameter mm 180 160 160 160 155 230 200 200 200 200 280 260 255 250 250

Bar diameter 2) mm 10 10 10 10 10 12 12 12 12 12 14 12 12 12 12

Length, approx. mm 185 185 185 185 185 254 256 231 231 231 282 281 281 281 281

Pitch mm 45 45 45 45 45 45 50 50 50 50 50 50 50 50 50

Number of pitches 5 5 5 5 5 6 6 5 5 5 6 6 6 6 6

Distance E mm 15 15 15 15 15 18 18 18 18 18 20 20 20 20 20

Additional reinforcement

Number of stirrups 3 3 4 4 3 5 4 4 4 4 5 5 5 4 5

Bar diameter 2) mm 12 12 10 10 12 14 14 12 14 14 12 14 12 14 14

Spacing mm 60 55 45 45 55 55 60 55 55 55 60 55 55 65 55

Distance from bearing trumplate

F mm 30 30 30 30 30 33 33 33 33 33 35 35 35 35 35

Outer dimensions B B mm 220 200 190 190 190 290 270 240 240 240 330 300 290 290 290


Min. centre spacing ac, bc mm 235 215 210 210 205 310 285 260 255 255 350 320 310 310 310

Min. edge distance,

plus c a'e, b'e mm 110 100 95 95 95 145 135 120 120 120 165 150 145 145 145

1) Prestressing strand with nominal diameter of 15.3 mm, cross-sectional area of 140 mm2 or with characteristic tensile strength below 1 860 MPa may also be used.

2) Bar diameter of 14 mm can be replaced by 16 mm.

CONA CME


Anchorage zone – Dimensions Helix and additional reinforcement and spacing

Annex 18


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021



B

B F

E

ca'e a'e

ae ae

c

be

bc

c a'e

ae ac

c

be

bc

b' e

b' e

c




Strand arrangement

Strand 1) mm2 150 150 150

Cross-sectional area mm2 1 800 2 250 2 850

Charact. tensile strength Rm MPa 1 860 1 860 1 860


0.90 · Fp0.1 kN 2 657 3 321 4 207

0.95 · Fp0.1 kN 2 804 3 506 4 440



fcm, 0 MPa 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43


fcm, 0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

Helix


Bar diameter 2) mm 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14

Length, approx. mm 332 332 332 332 282 432 432 382 332 332 457 457 432 432 382

Pitch mm 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50


Distance E mm 20 20 20 20 20 27 27 27 27 27 27 27 27 27 27



Bar diameter 2) mm 12 14 16 16 14 14 16 16 16 16 16 16 16 16 16

Spacing mm 60 55 70 70 50 60 65 65 55 60 65 65 65 65 60


F mm

35 35 35 35 35 42 42 42 42 42 42 42 42 42 42




Min. edge distance,

plus c a'e, b'e mm 195 175 160 155 145 220 200 180 175 175 245 225 205 195 185



CONA CME



Annex 19


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021



B

B F

E

ca'e a'e

ae ae

c

be

bc

c a'e

ae ac

c

be

bc

b' e

b' e

c




Strand arrangement

Strand 1) mm2 150 150 150




0.90 · Fp0.1 kN 4 871 5 314 5 978

0.95 · Fp0.1 kN 5 141 5 609 6 310



fcm, 0 MPa 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43


fcm, 0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

Helix


Bar diameter 2) mm 14 14 14 14 14 14 14 14 14 14 14 14 14 14 14

Length, approx. mm 482 482 432 432 382 532 532 482 482 432 532 532 482 482 432

Pitch mm 50 50 50 50 50 50 50 50 50 50 50 50 50 50 50


Distance E mm 31 31 31 31 31 32 32 32 32 32 35 35 35 35 35



Bar diameter 2) mm 20 20 20 20 16 20 20 20 20 20 20 20 20 20 20

Spacing mm 80 75 65 65 50 80 80 70 65 55 80 80 75 60 60


F mm

46 46 46 46 46 47 47 47 47 47 50 50 50 50 50




Min. edge distance,

plus c a'e, b'e mm 265 240 220 210 200 280 255 230 220 210 295 270 245 235 220



CONA CME



Annex 20


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021



B

B F

E

ca'e a'e

ae ae

c

be

bc

c a'e

ae ac

c

be

bc

b' e

b' e

c




Strand arrangement

Strand 1) mm2 150 150 150




0.90 · Fp0.1 kN 6 863 8 192 9 299

0.95 · Fp0.1 kN 7 245 8 647 9 815



fcm, 0 MPa 23 28 34 38 43 23 28 34 38 43 23 28 34 38 43


fcm, 0 MPa 19 23 28 31 35 19 23 28 31 35 19 23 28 31 35

Helix

Outer diameter mm 560 520 475 430 430 580 580 580 580 630 630 630 630

Bar diameter 2) mm 14 14 14 14 14 16 16 16 16 16 16 16 16

Length, approx. mm 532 532 582 482 432 533 533 533 533 583 583 583 583

Pitch mm 50 50 50 50 50 50 50 50 50 50 50 50 50

Number of pitches 11 11 12 10 9 11 11 11 11 12 12 12 12

Distance E mm 35 35 35 35 35 40 40 40 40 45 45 45 45


Number of stirrups 9 8 8 8 8 9 9 9 9 10 10 10 10

Bar diameter 2) mm 20 20 20 20 20 20 20 20 20 20 20 20 20

Spacing mm 80 75 70 65 60 70 70 70 70 70 70 70 70


F mm

50 50 50 50 50 50 50 50 50 55 55 55 55

Outer dimensions B B mm 630 580 530 500 480 660 660 660 660 720 720 720 720


Min. centre spacing ac, bc mm 650 595 545 520 495 680 680 680 680 735 735 735 735

Min. edge distance,

plus c a'e, b'e mm 315 290 265 250 240 330 330 330 330 360 360 360 360



CONA CME



Annex 21


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021



B

B F

E

ca'e a'e

ae ae

c

be

bc

c a'e

ae ac

c

be

bc

b' e

b' e

c



BBR VT CONA CMI 43 48

Strand arrangement

Strand 1) mm2 150 150

Cross-sectional area mm2 6 450 7 200

Charact. tensile strength Rm MPa 1 860 1 860

Charact. maximum force Fm kN 11 997 13 392

0.90 · Fp0.1 kN 9 520 10 627

0.95 · Fp0.1 kN 10 049 11 218



fcm, 0 MPa 23 28 34 38 43 23 28 34 38 43


fcm, 0 MPa 19 23 28 31 35 19 23 28 31 35

Helix

Outer diameter mm 670 670 670 670 710 710 710 710

Bar diameter 2) mm 16 16 16 16 16 16 16 16

Length, approx. mm 583 583 583 583 633 633 633 633

Pitch mm 50 50 50 50 50 50 50 50

Number of pitches 12 12 12 12 13 13 13 13

Distance E mm 45 45 45 45 45 45 45 45


Number of stirrups 10 10 10 10 11 11 11 11

Bar diameter 2) mm 20 20 20 20 20 20 20 20

Spacing mm 70 70 70 70 70 70 70 70

Distance from bearing trumplate F mm 55 55 55 55 55 55 55 55

Outer dimensions B B mm 740 740 740 740 790 790 790 790


Min. centre spacing ac, bc mm 755 755 755 755 805 805 805 805

Min. edge distance, plus c a'e, b'e mm 370 370 370 370 395 395 395 395



CONA CME



Annex 22


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021



B

B F

E

ca'e a'e

ae ae

c

be

bc

c a'e

ae ac

c

be

bc

b' e

b' e

c



BBR VT CONA CMI 55 61

Strand arrangement

Strand 1) mm2 150 150

Cross-sectional area mm2 8 250 9 150

Charact. tensile strength Rm MPa 1 860 1 860

Charact. maximum force Fm kN 15 345 17 019

0.90 · Fp0.1 kN 12 177 13 505

0.95 · Fp0.1 kN 12 854 14 256



fcm, 0 MPa 23 28 34 38 43 23 28 34 38 43


fcm, 0 MPa 19 23 28 31 35 19 23 28 31 35

Helix

Outer diameter mm 780 780 780 780 850 850 850 850

Bar diameter 2) mm 20 20 20 20 20 20 20 20

Length, approx. mm 760 760 760 760 790 790 790 790

Pitch mm 60 60 60 60 60 60 60 60

Number of pitches 13 13 13 13 14 14 14 14

Distance E mm 50 50 50 50 55 55 55 55


Number of stirrups 11 11 11 11 12 12 12 12

Bar diameter 2) mm 20 20 20 20 20 20 20 20

Spacing mm 75 75 75 75 75 75 75 75

Distance from bearing trumplate F mm 55 55 55 55 60 60 60 60

Outer dimensions B B mm 860 860 860 860 920 920 920 920


Min. centre spacing ac, bc mm 875 875 875 875 940 940 940 940

Min. edge distance, plus c a'e, b'e mm 430 430 430 430 460 460 460 460



CONA CME



Annex 23


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OIB-205-058/17-021


be

bc

ae ac

c

c

be

bc

ae ac

c

ca'e

b' e

a'e_

b' e_

ac, bc ae, be

ac bc

ae be

Modification of centre spacing and edge distance are in accordance with Clause 1.9.

bc_ 0.85 bc

and

Helix, outside diameter 1)

ac_ Ac

bc_

Ac = ac · bc ac_ · bc_

Corresponding edge distances

ae– =

ac–

2 10 mm + c

and

be– =

bc–

2 10 mm + c

c ..... Concrete cover

1) Except the dimensions of helix, which remain unchanged, the outer dimensions of additional stirrup reinforcement are adjusted accordingly. Further modifications of reinforcement are in accordance with the Clauses 1.14.8 and 2.2.3.4.

CONA CME


Anchorage zone – Dimensions Modification of centre spacing and edge distance

Annex 24


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OIB-205-058/17-021

Stressing anchorage, recessed

Stressing anchorage, exposed

Fixed coupler FK

1. BA

1st construction stage

2. BA

2nd construction stage

Fixed coupler FH

1. BA

1st construction stage

2. BA

2nd construction stage

CONA CME


Construction stages

Annex 25


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OIB-205-058/17-021

Stressing anchorage with monostrand, recessed

Stressing anchorage with monostrand, exposed

CONA CME


Construction stages

Annex 26


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OIB-205-058/17-021

1 Preparatory work

The components of the post-tensioning kit are stored so as to avoid any damage or corrosion.

2 Anchorage recesses

Adequate space to accommodate and to use the prestressing jack is ensured, see also the Clauses 1.4 and 2.2.3.2.

3 Fastening the bearing trumplates

Four holes are provided to fasten the bearing trumplates to the formwork. The trumpet is screwed into the bearing trumplate. The helix is either welded to the bearing trumplate by means of radial bars, see also the Clauses 1.14.8, 2.2.3.4, and 2.2.4.8, or positioned by fixing it to the existing reinforcement. The trumpet and a piece of the duct are connected in a waterproof way. In the final position the duct protrudes at least 100 mm out of the formwork.

4 Installation of deviators

For accurate installation it is recommended to use a guide wire or something equivalent between successive deviators for pre-adjustment. The deviator is properly connected to the formwork and the reinforcement mesh to avoid any movement during concreting. If required, recess units are inserted in the deviator to avoid deformations. The minimum radii of curvature complies with Clause 1.10.

5 Placing of ducts The ducts are placed on supports with a spacing of 2 m to 4 m by taking into account the increase of weight due to the tensile elements. The ducts are jointed in a leak-proof way, see also the Clauses 1.6 and 2.2.4.8. In the case of plastic ducts at least one telescopic joint is installed do adjust the length of the duct to the tendon. This opening will be jointed after stressing.

6 Installation of tensile elements, prestressing steel

The prestressing steel is pushed or pulled into the duct before or after concreting of the structure.

7 Installation of the inaccessible fixed anchorages

After passing the strands through the anchor head, they are anchored individually in the cones by means of ring wedges. After assembling the wedges are secured in accordance with the Clauses 1.2.2.1 and 1.14.7.

8 Installation of fixed coupler anchor head 2.BA

The function of the fixed coupler is to connect two tendons, whereas the first tendon is stressed before the second tendon is installed and stressed.

The coupling is achieved by pushing the strands into the already tensioned coupler anchor head K, side 2.BA in the outer pitch circle, whereby the strands are marked to check the correct depth of engagement.

The coupler anchor head H, 2.BA is assembled with ring wedges which are secured in accordance with the Clauses 1.14.5 and 1.14.7. It is connected to the already tensioned coupler anchor head H, 1.BA by means of a threaded coupler sleeve.

CONA CME


Description of installation

Annex 27


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OIB-205-058/17-021

9 Assembly of anchor head/coupler anchor head 1.BA

After passing the strands through the anchor head, they are anchored individually in the cones by means of ring wedges. The same applies for the coupler anchor head in case of fixed couplers in the first construction stage.

10 Prestressing

At the time of stressing the mean concrete compressive strength is at least according to Table 5 and the data of Clause 1.11. Stressing and possible wedging are carried out with a suitable prestressing jack and in accordance with Clause 2.2.4.2.

Elongation of the tendon and prestressing forces are checked and recorded systematically during the stressing operation.

Restressing the tendons is permitted in accordance with Clause 2.2.4.4.

11 Grouting the tendons

The grout is injected through the inlet holes until it escapes from the outlet tubes with the same consistency. All vents and grouting inlets are sealed immediately after grouting, see also Clause 2.2.4.6.1.

Grease and way are injected in accordance with ETAG 013 and the recommendations of the supplier, see also Clause 2.2.4.6.2.

More detailed information on installation can be obtained from the ETA holder.

CONA CME


Description of installation

Annex 28


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Contents of the prescribed test plan

Component Item Test / Check

Trace-ability

Minimum frequency

Documentation

Bearing trumplate,

Bearing trumplate E

Material Check

Full

100 % "3.1" 1)

Detailed dimensions Test 3 %

2 specimens Yes

Visual inspection 2) Check 100 % No

Anchor head, Coupler anchor head

Material Check

Full

100 % "3.1" 1)

Detailed dimensions 3) Test 5 %

2 specimens Yes

Visual inspection 2), 4) Check 100 % No

Ring wedge Material Check

Full

100 % "3.1" 1)

Treatment, hardness 5), 6) Test 0.5 %

2 specimens Yes

Detailed dimensions Test 5 %

2 specimens Yes

Visual inspection 2), 7) Check 100 % No

Steel ring Material Check

Bulk

100 % "2.2" 8)

Detailed dimensions Test

0.5 %

2 specimens Yes


Coupler sleeve Material Check

Full

100 % "3.1" 1)

Detailed dimensions Test

5 %

2 specimens Yes


Steel duct Material Check Bulk

100 % "2.2" 8)


Strand 9) Material Check

Full

100 % "CE" 9)

Diameter Test Each coil No

Visual inspection 2) Check Each coil No

Constituents of filling material as per EN 447

Cement Check Full 100 % "CE"

Admixtures, additions Check Bulk 100 % "CE"

Components for EIT Material Check Full

100 % MC 10)


1) "3.1": Inspection certificate type "3.1" according to EN 10204 2) Visual inspections includes e.g. main dimensions, gauge testing, correct marking or labelling, appropriate

performance, surface, fins, kinks, smoothness, corrosion, coating, etc., as detailed in the prescribed test plan. 3) Other dimensions than 4) 4) Dimensions: All conical bores of the anchor heads and coupler anchor heads regarding angle, diameter and surface

condition, thread dimensions of all anchor heads and coupler anchor heads 5) Geometrical properties 6) Surface hardness 7) Teeth, cone surface 8) "2.2": Test report type "2.2" according to EN 10204 9) As long as the basis for CE marking for prestressing steel is not available, an approval or certificate according to the

respective standards and regulations in force at the place of use accompanies each delivery. 10) Certificate of the manufacturer of the material that allow for proof of conformity. Full .......... Full traceability of each component to its raw materials Bulk ......... Traceability of each delivery of components to a defined point

CONA CME


Contents of the prescribed test plan

Annex 29


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Audit testing

Component Item Test / Check

Sampling 2) – Number of

components per visit

Anchor head, Coupler anchor head, Bearing trumplate, Bearing trumplate E, Steel ring

Material according to specification

Test / Check

1 Detailed dimensions Test

Visual inspection 1) Check

Coupler sleeve Material according to specification

Test / Check

1 Detailed dimensions Test

Visual inspection 1) Check

Ring wedge Material according to specification

Test / Check

2

Treatment Test 2

Detailed dimensions Test 1

Main dimensions, surface hardness and

surface finish Test 5

Visual inspection 1) Check 5

Single tensile element test

Single tensile element test according to

ETAG 013, Annex E.3 Test 1 series

1) Visual inspections means e.g. main dimensions, gauge testing, correct marking or labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion protection, corrosion, coating, etc., as given in the prescribed test plan.

2) All samples are randomly selected and clearly identified.

CONA CME


Audit testing

Annex 30


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

№ Essential Characteristic Clause

Intended use

Line № according to Clause 2.1, Table 7

1 2 3 4 5 6

1 Resistance to static load 3.2.1.1 + + + + + +

2 Resistance to fatigue 3.2.1.2 + + + + + +

3 Load transfer to the structure 3.2.1.3 + + + + +

4 Friction coefficient 3.2.1.4 + + + + + +

5 Deviation, deflection (limits) 3.2.1.5 + + + + + +

6 Practicability, reliability of installation 3.2.1.6 + + + + + +

7 Content, emission, and/or release of

dangerous substances 3.2.2 + + + + + +

8 Related aspects of serviceability 3.2.3 + + + + + +

9 Practicability, reliability of installation 3.2.4.1 +



12 Load transfer to the structure 3.2.4.4 +

Key + .................. Essential characteristic relevant for the intended use

................ Essential characteristic not relevant for the intended use

For combinations of intended uses the essential characteristics of all intended uses composing the combination are relevant.

CONA CME


Essential characteristics for the intended uses

Annex 31


ETA-07/0168 of 18.12.2017



OIB-205-058/17-021

Reference documents

Guideline for European Technical Approval

ETAG 013, 06.2002 Guideline for European Technical Approval of Post-Tensioning Kits for Prestressing of Structures

Standards

EN 206, 12.2013 Concrete – Specification, performance, production and conformity

EN 445, 10.2007 Grout for prestressing tendons – Test methods

EN 446, 10.2007 Grout for prestressing tendons – Grouting procedures

EN 447, 10.2007 Grout for prestressing tendons – Basic requirements

EN 1561, 10.2011 Founding – Grey cast irons

EN 1563, 12.2011 Founding – Spheroidal graphite cast irons

Eurocode 2 Eurocode 2: Design of concrete structures

Eurocode 3 Eurocode 3: Design of steel structures

Eurocode 4 Eurocode 4: Design of composite steel and concrete structures

Eurocode 6 Eurocode 6: Design of masonry structures

EN 10025-2, 11.2004 EN 10025-2/AC, 06.2005

Hot rolled products of structural steels – Part 2: Technical delivery conditions for non-alloy structural steels

EN 10083-1, 08.2006 Steels for quenching and tempering – Part 1: General technical delivery conditions

EN 10083-2, 08.2006 Steels for quenching and tempering – Part 2: Technical delivery conditions for non alloy steels

EN 10084, 04.2008 Case hardening steels – Technical delivery conditions

EN 10204, 10.2004 Metallic products – Types of inspection documents

EN 10210-1, 04.2006 Hot finished structural hollow sections of non-alloy and fine grain steels – Part 1: Technical delivery conditions

EN 10216-1, 12.2013 Seamless steel tubes for pressure purposes – Technical delivery conditions – Part 1: Non-alloy steel tubes with specified room temperature properties

EN 10217-1, 05.2002 EN 10217-1/A1, 01.2005

Welded steel tubes for pressure purposes – Technical delivery conditions – Part 1: Non-alloy steel tubes with specified room temperature properties

EN 10219-1, 04.2006 Cold formed welded structural hollow sections of non-alloy and fine grain steels – Part 1: Technical delivery conditions

EN 10255+A1, 04.2007 Non-Alloy steel tubes suitable for welding and threading – Technical delivery conditions

EN 10270-1, 10.2011 Steel wire for mechanical springs – Part 1: Patented cold drawn unalloyed steel wire

EN 10277-2, 03.2008 Bright steel products – Technical delivery conditions – Part 2: Steels for general engineering purposes

CONA CME


Reference documents

Annex 32


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OIB-205-058/17-021

EN 10305-5, 01.2010 Steel tubes for precision applications – Technical delivery conditions – Part 5: Welded cold sized square and rectangular tubes

EN 12201-1, 09.2011 Plastics piping systems for water supply, and for drainage and sewerage under pressure – Polyethylene (PE) – Part 1: General

ENV 1992-1-5, 10.1994 Eurocode 2: Design of concrete structures – Part 1-5: General rules – Structures with unbonded and external prestressing tendons

EN ISO 17855-1, 10.2014 Plastics – Polyethylene (PE) moulding and extrusion materials – Part 1: Designation system and basis for specifications

EN ISO 19069-1, 03.2015 Plastics – Polypropylene (PP) moulding and extrusion materials – Part 1: Designation system and basis for specifications

prEN 10138-3, 09.2000 Prestressing steels – Part 3: Strand

prEN 10138-3, 08.2009 Prestressing steels – Part 3: Strand

CWA 14646, 01.2003 Requirements for the installation of post-tensioning kits for prestressing of structures and qualification of the specialist company and its personnel

98/456/EC Commission decision 98/456/EC of 3 July 1998 on the procedure for attesting the conformity of construction products pursuant to Article 20 (2) of Council Directive 89/106/EEC as regards posttensioning kits for the prestressing of structures, Official Journal of the European Communities L 201 of 17 July 1998, p. 112

305/2011 Regulation (EU) № 305/2011 of the European Parliament and of the Council of 9 March 2011 laying down harmonised conditions for the marketing of construction products and repealing Council Directive 89/106/EEC, OJ L 88 of 4 April 2011, p. 5, amended by Commission Delegated Regulation (EU) № 568/2014 of 18 February 2014, OJ L 157 of 27.05.2014, p. 76 and Commission Delegated Regulation (EU) № 574/2014 of 21 February 2014, OJ L 159 of 28.05.2014, p. 41

568/2014 Commission Delegated Regulation (EU) № 568/2014 of 18 February 2014 amending Annex V to Regulation (EU) № 305/2011 of the European Parliament and of the Council as regards the assessment and verification of constancy of performance of construction products, OJ L 157 of 27.05.2014, p. 76

CONA CME


Reference documents

Annex 33


ETA-07/0168 of 18.12.2017

BBR VT International LtdTechnical Headquarters and Business Development CentreSwitzerland

Cop

yrig

ht B

BR

VT

Inte

rnat

iona

l 02.

2018

KB Vorspann-Technik GmbH Weitwörth 25 5151 Nussdorf a. H. Austria

Tel +43 6272 40790 Fax +43 6272 40790 11

www.kb-vt.com [email protected]

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